Structured Fibrous Web

ABSTRACT

The present disclosure is directed to disposable absorbent articles comprising a structured fibrous web, the structured fibrous web comprising thermally stable, hydrophilic fibers that are thermally bonded together using heat producing a base substrate that is thermally stable. The base substrate is textured via mechanical treatment to increase its thickness and optionally modified via over bonding to improve its mechanical and fluid handling properties. The structured fibrous web provides optimal fluid wicking and fluid acquisition capabilities and is directed toward fluid management applications.

FIELD OF THE INVENTION

The present invention is related to fibrous webs, particularlystructured fibrous webs providing optimal fluid acquisition anddistribution capabilities.

BACKGROUND OF THE INVENTION

Commercial nonwoven fabrics typically comprise synthetic polymers formedinto fibers. These fabrics are typically produced with solid fibers thathave a high inherent overall density, typically 0.9 g/cm³ to 1.4 g/cm³.The overall weight or basis weight of the fabric is often dictated by adesired opacity, mechanical properties, softness/cushiness, or aspecific fluid interaction of the fabric to promote an acceptablethickness or caliper, strength and protection perception. Often, theseproperties are needed in combination to achieve a particular function ora desired level of performance.

Functionality of nonwoven fabrics is important for many applications.For many nonwoven applications, its function is to provide a desiredfeel to a product by making it softer or feel more natural. For othernonwoven applications, its function affects the direct performance ofthe product by making it absorbent or capable of acquiring ordistributing fluid. In either case, the function of the nonwoven isoften related to the caliper or thickness. For instance, nonwovenfabrics are useful for fluid management applications desiring optimalfluid acquisition and distribution capabilities. Such applicationsinclude use in disposable absorbent articles for wetness protection andcleaning applications for fluid and particulate clean-up. In either casenonwoven fabrics are desired for use as a fluid management layer havingcapacity to acquire and distribute fluid.

The effectiveness of the nonwoven fabric in performing this function islargely dependent upon the thickness or caliper and corresponding voidvolume of the nonwoven fabric as well as the properties of the fibersused to form it. For many applications caliper also needs to be limitedso that bulkiness of the resulting product is minimized. For instance, adisposable absorbent article typically includes a nonwoven topsheet abacksheet and an absorbent core therebetween. In order to controlleakage and rewet due to gushing, a fluid acquisition layer thattypically comprises at least one nonwoven layer is disposed between thetopsheet and the absorbent core. The acquisition layer has capacity totake in fluid and transport it to the absorbent core. The effectivenessof the acquisition layer in performing this function is largelydependent upon the thickness of the layer and the properties of thefibers used to form it. However, thickness leads to bulkiness which isundesirable to the consumer. Therefore, the thickness or caliper of anonwoven is selected based on a balance of maximum thickness forfunctionality and minimal thickness for comfort.

In addition, the caliper of a nonwoven fabric is often difficult tomaintain due to compressive forces induced during material handling,storage and in some applications, ordinary use. Therefore, for mostapplications it is desirable for a nonwoven to exhibit a robust caliperthat is sustainable through converting, packaging and end use. What'smore, high caliper nonwoven fabrics take up more space on rolls duringstorage. Thus, it is also desirable have a process for increasing thecaliper of a nonwoven fabric preferably not until the point in time whenit enters the process used in manufacturing a particular end product sothat more material can be stored on a roll before it is converted to afinal product.

SUMMARY OF THE INVENTION

The present invention is directed to a disposable absorbent articlescomprising one or more structured fibrous web(s), the structured fibrousweb comprising thermally stable fibers. The fibers and the fibrous webare preferably non extensible. The fibers are non extensible so thatthey break in the plane of the web during mechanical treatment asdescribed below and stiff to withstand compressive forces during use.The fibers have a modulus of at least 0.5 GPa. The fibers are thermallybonded together using heat, producing a fibrous web base substrate thatis thermally stable.

The fibrous web base substrate has a characteristic loft or thickness,based on the fiber size, basis weight and bonding type that isessentially homogenous over a large area. The base substrate includes afirst surface and a second surface that are mechanically treated toimpart localized out of plane thickness to the base substrate forming astructured fibrous web. The structured fibrous web comprises a firstregion and a plurality of discrete second regions disposed throughoutthe first region. The second regions form discontinuities on the secondsurface of the fibrous web and displaced fibers on the first surface.The displaced fibers are fixed along a first side of the second regionand are separated proximate to the first surface along a second side ofthe second region opposite the first side forming loose ends extendingaway from the first surface of the fibrous fabric. At least 50% and lessthan 100% of the displaced fibers have loose ends providing free volumefor collecting fluid.

In one embodiment the structured fibrous web includes a plurality ofbonded and/or overbonded regions disposed throughout the first region inbetween the second regions. The bonded and/or overbonded regions cancontinuously extend between the second regions forming depressions whichprovide additional void volume for fluid acquisition and channels forfluid distribution.

The structured fibrous web is directed toward fluid managementapplications desiring optimal fluid acquisition and distributioncapabilities.

The present invention provides a disposable absorbent article which maycomprise a chassis and an absorbent core. The chassis may contain atopsheet and a backsheet. The absorbent core may be located between thetopsheet and the backsheet. The disposable absorbent article furthercomprises an acquisition system between the topsheet and the absorbentcore.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying drawings where:

FIG. 1 is a schematic representation of an apparatus for making a webaccording present invention.

FIG. 1A is a schematic representation of an alternate apparatus formaking a laminate web according to the present invention.

FIG. 2 is an enlarged view of a portion of the apparatus shown in FIG.1.

FIG. 3 is a partial perspective view of a structured substrate.

FIG. 4 is an enlarged portion of the structured substrate shown in FIG.3.

FIG. 5 is a cross-sectional view of a portion of the structuredsubstrate shown in FIG. 4.

FIG. 6 is a plan view of a portion of the structured substrate shown inFIG. 5.

FIG. 7 is a cross-sectional depiction of a portion of the apparatusshown in FIG. 2.

FIG. 8 is a perspective view of a portion of the apparatus for formingone embodiment the web of the present invention.

FIG. 9 is an enlarged perspective view of a portion of the apparatus forforming the web of the present invention.

FIG. 10 is a partial perspective view of a structured substrate havingmelt-bonded portions of displaced fibers.

FIG. 11 is an enlarged portion of the structured substrate shown in FIG.10.

FIG. 12 a-12 f are plan views of a portion of the structured substrateof the present invention illustrating various patterns of bonded and/orover bond regions.

FIG. 13 is a cross-sectional view of a portion of the structuredsubstrate showing bonded and/or over bond regions.

FIG. 14 is a cross-sectional view of a portion of the structuredsubstrate showing bonded and/or over bond regions on opposing surfacesof the structured substrate.

FIG. 15 is a photomicrograph of a portion of a web of the presentinvention showing tent-like structures formed at low fiber displacementdeformations.

FIG. 16 is a photomicrograph of a portion of a web of the presentinvention showing substantial fiber breakage resulting from increasedfiber displacement deformation.

FIG. 17 a and 17 b are photomicrographs of portions of a web of thepresent invention showing portions of the structured substrate that arecut in order to determine the number of displaced fibers.

FIG. 18 is a photomicrograph of a portion of a web of the presentinvention identifying locations along tip bonded displaced fibers of thestructured substrate that are cut in order to determine the number ofdisplaced fibers.

FIG. 19 a through 19 c are cross sections of shaped fiberconfigurations.

FIG. 20 is a schematic representation of an in plane radial permeabilityapparatus set up.

FIG. 21A, 21B and 21C are alternate views of a portion of the in planeradial permeability apparatus set up shown in FIG. 20.

FIG. 22 is a schematic representation of a fluid delivery reservoir forthe in plane radial permeability apparatus set up shown in FIG. 20.

FIG. 23 is a plan view of a diaper in accordance with an embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION Definitions:

As used herein the term “activation” means any process by which tensilestrain produced by intermeshing teeth and grooves causes intermediateweb sections to stretch or extend. Such processes have been found usefulin the production of many articles including breathable films, stretchcomposites, apertured materials and textured materials. For nonwovenwebs, the stretching can cause fiber reorientation, change in fiberdenier and/or cross section, a reduction in basis weight, and/orcontrolled fiber destruction in the intermediate web sections. Forexample, a common activation method is the process known in the art asring rolling.

As used herein “depth of engagement” means the extent to whichintermeshing teeth and grooves of opposing activation members extendinto one another.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven webs or fabrics havebeen formed from many processes, such as, for example, meltblowingprocesses, spunbonding processes, hydroentangling, airlaid, and bondedcarded web processes, including carded thermal bonding. The basis weightof nonwoven fabrics is usually expressed in grams per square meter(g/m²). The basis weight of a laminate web is the combined basis weightof the constituent layers and any other added components. Fiberdiameters are usually expressed in microns; fiber size can also beexpressed in denier, which is a unit of weight per length of fiber. Thebasis weight of the nonwoven fabrics or laminate webs suitable for usein the present invention can range from 6 g/m² to 300 g/m², preferablyfrom 10 g/m² to 200 g/m², more preferably from 15 g/m² to 120 g/m² andmost preferably from 20 g/m² to 100 g/m².

As used herein, “spunbond fibers” refers to relatively small diameterfibers which are formed by extruding molten thermoplastic material asfilaments from a plurality of fine, usually circular capillaries of aspinneret with the diameter of the extruded filaments then being rapidlyreduced by an externally applied force. Spunbond fibers are generallynot tacky when they are deposited on a collecting surface. Spunbondfibers are generally continuous and have average diameters (from asample of at least 10) larger than 7 microns, and more particularly,between about 10 and 40 microns.

As used herein, the term “meltblowing” refers to a process in whichfibers are formed by extruding a molten thermoplastic material through aplurality of fine, usually circular, die capillaries as molten threadsor filaments into converging high velocity, usually heated, gas (forexample air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface,often while still tacky; to form a web of randomly dispersed meltblownfibers. Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally smaller than 10 microns in averagediameter.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. In addition, unless otherwise specificallylimited, the term “polymer” includes all possible geometricconfigurations of the material. The configurations include, but are notlimited to, isotactic, atactic, syndiotactic, and random symmetries.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

As used herein, the term “bicomponent fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bicomponentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebicomponent fibers and extend continuously along the length of thebicomponent fibers. The configuration of such a bicomponent fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement.

As used herein, the term “biconstituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Biconstituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibers which start and end at random.Biconstituent fibers are sometimes also referred to as multiconstituentfibers.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and include “shaped fibers” and “capillarychannel fibers.” Such fibers can be solid or hollow, and they can betri-lobal, delta-shaped, and are preferably fibers having capillarychannels on their outer surfaces. The capillary channels can be ofvarious cross-sectional shapes such as “U-shaped”, “H-shaped”,“C-shaped” and “V-shaped”. One preferred capillary channel fiber isT-401, designated as 4DG fiber available from Fiber InnovationTechnologies, Johnson City, Tenn. T-401 fiber is a polyethyleneterephthalate (PET polyester).

“Disposed” refers to the placement of one element of an article relativeto another element of an article. For example, the elements may beformed (joined and positioned) in a particular place or position as aunitary structure with other elements of the diaper or as a separateelement joined to another element of the diaper.

“Extensible nonwoven” is a fibrous nonwoven web that elongates, withoutrupture or breakage, by at least 50%. For example, an extensiblematerial that has an initial length of 100 mm can elongate at least to150 mm, when strained at 100% per minute strain rate when tested at23±2° C. and at 50±2% relative humidity. A material may be extensible inone direction (e.g. CD), but non-extensible in another direction (e.g.MD). An extensible nonwoven is generally composed of extensible fibers.

“Highly extensible nonwoven” is a fibrous nonwoven web that elongates,without rupture or breakage, by at least 100%. For example, a highlyextensible material that has an initial length of 100 mm can elongate atleast to 200 mm, when strained at 100% per minute strain rate whentested at 23±2° C. and at 50±2% relative humidity. A material may behighly extensible in one direction (e.g. CD), but non-extensible inanother direction (e.g. MD) or extensible in the other direction. Ahighly extensible nonwoven is generally composed of highly extensiblefibers.

“Non-extensible nonwoven” is a fibrous nonwoven web that elongates, withrupture or breakage, before 50% elongation is reached. For example, anon-extensible material that has an initial length of 100 mm cannotelongate more than 50 mm, when strained at 100% per minute strain ratewhen tested at 23±2° C. and at 50±2% relative humidity. A non-extensiblenonwoven is non-extensible in both the machine direction (MD) and crossdirection (CD).

“Extensible fiber is a fiber that elongates by at least 400% withoutrupture or breakage, when strained at 100% per minute strain rate whentested at 23±2° C. and at 50±2% relative humidity.

“Highly extensible fiber” is a fiber that elongates by at least 500%without rupture or breakage, when strained at 100% per minute strainrate when tested at 23±2° C. and at 50±2% relative humidity.

“Non extensible fiber” is a fiber that elongates by less than 400%without rupture or breakage, when strained at 100% per minute strainrate when tested at 23±2° C. and at 50±2% relative humidity.

“Hydrophilic or hydrophilicity” refers to a fiber or nonwoven materialin which water or saline rapidly wets out on the surface the fiber orfibrous material. A material that wicks water or saline can beclassified as hydrophilic. A way for measuring hydrophilicity is bymeasuring its vertical wicking capability. For the present invention, anonwoven material is hydrophilic if it exhibits a vertical wickingcapability of at least 5 mm.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the otherelement, and configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) thatin turn are affixed to the other element.

“Laminate” means two or more materials that are bonded to one another bymethods known in the art, e.g. adhesive bonding, thermal bonding,ultrasonic bonding.

“Machine direction” or “MD” is the direction parallel to the directionof travel of the web as it moves through the manufacturing process.Directions within ±45 degrees of the MD are considered to be machinedirectional. The “cross machine direction” or “CD” is the directionsubstantially perpendicular to the MD and in the plane generally definedby the web. Directions within less than 45 degrees of the crossdirection are considered to be cross directional.

“Outboard” and “inboard” refer, respectively, to the location of anelement disposed relatively far from or near to the longitudinalcenterline of an absorbent article with respect to a second element. Forexample, if element A is outboard of element B, then element A isfarther from the longitudinal centerline than is element B.

“Wicking” refers to the active fluid transport of fluid through thenonwoven via capillary forces. Wicking rate refers to the fluid movementper unit time, or i.e., how far a fluid has traveled in a specifiedperiod of time.

“Acquisition rate” refers to the speed in which a material takes-up adefined quantity of fluid or the amount of time it takes for the fluidto pass through the material.

“Permeability” refers to a relative ability of a fluid to flow through amaterial in the X-Y plane. Materials with high permeability enablehigher fluid flow rates than materials with lower permeability.

“Web” means a material capable of being wound into a roll. Webs may befilms, nonwovens, laminates, apertured laminates, etc. The face of a webrefers to one of its two dimensional surfaces, as opposed to its edge.

“X-Y plane” means the plane defined by the MD and CD of a moving web orthe length.

“Absorbent article” refers to devices that absorb and contain bodyexudates, and, more specifically, refers to devices that are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Absorbent articles mayinclude diapers, pants, training pants, adult incontinenceundergarments, feminine hygiene products, and the like. As used herein,the term “body fluids” or “body exudates” includes, but is not limitedto, urine, blood, vaginal discharges, breast milk, sweat and fecalmatter. Preferred absorbent articles of the present invention arediapers, pants and training pants.

“Absorbent core” means a structure typically disposed between a topsheetand backsheet of an absorbent article for absorbing and containingliquid received by the absorbent article and may comprise one or moresubstrates, absorbent polymer material disposed on the one or moresubstrates, and a thermoplastic composition on the absorbent particulatepolymer material and at least a portion of the one or more substratesfor immobilizing the absorbent particulate polymer material on the oneor more substrates. In a multilayer absorbent core, the absorbent coremay also include a cover layer. The one or more substrates and the coverlayer may comprise a nonwoven. Further, the absorbent core issubstantially cellulose free. The absorbent core does not include anacquisition system, a topsheet, or a backsheet of the absorbent article.In a certain embodiment, the absorbent core would consist essentially ofthe one or more substrates, the absorbent polymer material, thethermoplastic composition, and optionally the cover layer.

“Absorbent polymer material,” “absorbent gelling material,” “AGM,”“superabsorbent,” and “superabsorbent material” are used hereininterchangeably and refer to cross linked polymeric materials that canabsorb at least 5 times their weight of an aqueous 0.9% saline solutionas measured using the Centrifuge Retention Capacity test (Edana441.2-01).

“Absorbent particulate polymer material” is used herein to refer to anabsorbent polymer material which is in particulate form so as to beflowable in the dry state.

“Airfelt” is used herein to refer to comminuted wood pulp, which is aform of cellulosic fiber.

“Comprise,” “comprising,” and “comprises” are open ended terms, eachspecifies the presence of what follows, e.g., a component, but does notpreclude the presence of other features, e.g., elements, steps,components known in the art, or disclosed herein.

“Consisting essentially of” is used herein to limit the scope of subjectmatter, such as that in a claim, to the specified materials or steps andthose that do not materially affect the basic and novel characteristicsof the subject matter.

“Disposable” is used in its ordinary sense to mean an article that isdisposed or discarded after a limited number of usage events overvarying lengths of time, for example, less than about 20 events, lessthan about 10 events, less than about 5 events, or less than about 2events.

“Diaper” refers to an absorbent article generally worn by infants andincontinent persons about the lower torso so as to encircle the waistand legs of the wearer and that is specifically adapted to receive andcontain urinary and fecal waste. As used herein, term “diaper” alsoincludes “pants” which is defined below.

“Pant” or “training pant”, as used herein, refer to disposable garmentshaving a waist opening and leg openings designed for infant or adultwearers. A pant may be placed in position on the wearer by inserting thewearer's legs into the leg openings and sliding the pant into positionabout a wearer's lower torso. A pant may be preformed by any suitabletechnique including, but not limited to, joining together portions ofthe article using refastenable and/or non-refastenable bonds (e.g.,seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may bepreformed anywhere along the circumference of the article (e.g., sidefastened, front waist fastened). While the terms “pant” or “pants” areused herein, pants are also commonly referred to as “closed diapers,”“prefastened diapers,” “pull-on diapers,” “training pants,” and“diaper-pants”. Suitable pants are disclosed in U.S. Pat. No. 5,246,433,issued to Hasse, et al. on Sep. 21, 1993; U.S. Pat. No. 5,569,234,issued to Buell et al. on Oct. 29, 1996; U.S. Pat. No. 6,120,487, issuedto Ashton on Sep. 19, 2000; U.S. Pat. No. 6,120,489, issued to Johnsonet al. on Sep. 19, 2000; U.S. Pat. No. 4,940,464, issued to Van Gompelet al. on Jul. 10, 1990; U.S. Pat. No. 5,092,861, issued to Nomura etal. on Mar. 3, 1992; U.S. Patent Publication No. 2003/0233082 A1,entitled “Highly Flexible And Low Deformation Fastening Device”, filedon Jun. 13, 2002; U.S. Pat. No. 5,897,545, issued to Kline et al. onApr. 27, 1999; U.S. Pat. No. 5,957,908, issued to Kline et al on Sep.28, 1999.

Regarding all numerical ranges disclosed herein, it should be understoodthat every maximum numerical limitation given throughout thisspecification includes every lower numerical limitation, as if suchlower numerical limitations were expressly written herein. In addition,every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Further, everynumerical range given throughout this specification will include everynarrower numerical range that falls within such broader numerical rangeand will also encompass each individual number within the numericalrange, as if such narrower numerical ranges and individual numbers wereall expressly written herein.

The present invention provides a structured substrate formed byactivation of a suitable base substrate. The activation induces fiberdisplacement and forms a three dimensional texture which increases thefluid acquisition properties of the base substrate. The surface energyof the base substrate can also be modified to increase its fluid wickingproperties. The structured substrate of the present invention will bedescribed with respect to a preferred method and apparatus used formaking the structured substrate from the base substrate. A preferredapparatus 150 is shown schematically in FIG. 1 and FIG. 2 and discussedmore fully below.

Base Substrate

The base substrate 20 according to the present invention is a fluidpermeable fibrous nonwoven web formed from a loose collection ofthermally stable fibers. The fibers according to the present inventionare non extensible which was previously defined as elongating by lessthan 300% without rupture or breakage; however, the non extensiblefibers forming the base substrate of the present invention preferablyelongate by less than 200% without rupture or breakage. The fibers caninclude staple fibers formed into a web using industry standard carding,airlaid, or wetlaid technologies; however, continuous spunbond fibersforming spunlaid nonwoven webs using industry standard spunbond typetechnologies is preferred. Fibers and spunlaid processes for producingspunlaid webs are discussed more fully below.

The fibers of the present invention may have various cross sectionalshapes that include, but are not limited to; round, elliptical, starshaped, trilobal, multilobal with 3-8 lobes, rectangular, H-shaped,C-shaped, I-shape, U-shaped and other various eccentricities. Hollowfibers can also be used. Preferred shapes are round, trilobal andH-shaped. Round fibers are the least expensive and are thereforepreferred from an economic standpoint but trilobal shaped fibers provideincreased surface area and are therefore preferred from a functionalstandpoint. The round and trilobal fiber shapes can also be hollow;however, solid fibers are preferred. Hollow fibers are useful becausethey have a higher compression resistance at equivalent denier than asolid fiber of the same shape and denier.

Fibers in the present invention tend to be larger than those found intypical spunbond nonwovens. Because the diameter of shaped fibers can behard to determine, the denier of the fiber is often referenced. Denieris defined as the mass of a fiber in grams at 9000 linear meters oflength, expressed as dpf (denier per filament). For the presentinvention, the preferred denier range is greater than 1 dpf and lessthan 100 dpf. A more preferred denier range is 1.5 dpf to 50 dpf and astill more preferred range from 2.0 dpf to 20 dpf, and a most preferredrange of 4 dpf to 10 dpf.

The loose collection of fibers forming the base substrate of the presentinvention are bonded in advance of activation and corresponding fiberdisplacement. A fibrous web can be under bonded so that the fibers havea high level of mobility and tend to pull out from the bond sites undertension or fully bonded with much higher bond site integrity such thatthe fibers exhibit minimal fiber mobility and tend to break undertension. The non extensible fibers forming the base substrate of thepresent invention are preferably fully bonded to form a non extensiblefibrous web material. As explained more fully below, a non extensiblebase substrate is preferred for forming the structured substrate viafiber displacement.

Fully bonding of the base substrate can be done in one bonding step,e.g. during manufacturing of the base substrate. Alternatively, therecan be more than one bonding step to make the pre-bonded base substrate,e.g., the base substrate can be only lightly bonded or under bonded uponmanufacturing to provide sufficient integrity to wind it up.Subsequently, the base substrate may then undergo further bonding stepsto obtain a fully bonded web, e.g., immediately prior to subjecting thebase substrate to the fiber displacement process of the presentinvention. Also, there may be bonding steps at any time between basesubstrate manufacture and fiber displacement. The different bondingsteps may also impart different bonding patterns.

Processes for bonding fibers are described in detail in “Nonwovens:Theory, Process, Performance and Testing” by Albin Turbak (Tappi 1997).Typical bonding methods include mechanical entanglement, hydrodynamicentanglement, needle punching, and chemical bonding and/or resinbonding; however, thermal bonding such as thru-air bonding utilizingheat and thermal point bonding utilizing pressure and heat are preferredwith thermal point bonding being most preferred.

Thru-air bonding is performed by passing a heated gas through acollection of fibers to produce a consolidated nonwoven web. Thermalpoint bonding involves applying heat and pressure to discrete locationsto form bond sites on the nonwoven web. The actual bond sites include avariety of shapes and sizes; including but not limited to oval, roundand four sided geometric shapes. The total overall thermal point bondarea is between 2% and 60%, preferably between 4% and 35%, morepreferably between 5% and 30% and most preferably between 8% and 20%. Afully bonded base substrate of the present invention has a total overallbond area of from 8% to 70%, preferably from 12% to 50%, and mostpreferably between 15% and 35%. The thermal point bonding pin density isbetween 5 pins/cm² and 100 pins/cm², preferably between 10 pins/cm² and60 pins/cm² and most preferably between 20 pins/cm² and 40 pins/cm². Afully bonded base substrate of the present invention has a bonding pindensity of from 10 pins/cm² to 60 pins/cm², preferably from 20 pins/cm²to 40 pins/cm².

Thermal bonding requires fibers formed from thermally bondable polymers,such as thermoplastic polymers and fiber made therefrom. For the presentinvention, the fiber composition includes a thermally bondable polymer.The preferred thermally bondable polymer comprises polyester resin,preferably PET resin, more preferably PET resin and coPET resinproviding thermally bondable, thermally stable fibers as discussed morefully below. For the present invention, the thermoplastic polymercontent is present at a level of greater than about 30%, preferablygreater than about 50%, more preferably greater than about 70%, and mostpreferably greater than about 90% by weight of the fiber.

As a result of bonding, the base substrate has mechanical properties inboth the machine direction (MD) and cross machine direction (CD). The MDtensile strength is between 1 N/cm and 200 N/cm, preferably between 5N/cm and 100 N/cm, more preferably between 10 N/cm and 50 N/cm and mostpreferably between 20 N/cm and 40 N/cm. The CD tensile strength isbetween 0.5 N/cm and 50 N/cm, preferably between 2 N/cm and 35 N/cm, andmost preferably between 5 N/cm and 25 N/cm. The base substrate shouldalso have a characteristic ratio of MD to CD tensile strength ratiobetween 1.1 and 10, preferably between 1.5 and 6 and most preferablybetween 1.8 and 5.

The bonding method also influences the thickness of the base substrate.The base substrate thickness or caliper is also dependent on the number,size and shape of fiber present in a given measured location. The basesubstrate thickness is between 0.10 mm and 1.3 mm, more preferablybetween 0.15 mm and 1.0 mm and most preferably between 0.20 mm and 0.7mm.

The base substrate also has a characteristic opacity. Opacity is ameasure of the relative amount of light that passes through the basesubstrate. Without wishing to be bound by theory, it is believed thatthe characteristic opacity depends on the number, size, type,morphology, and shape of fibers present in a given measured location.Opacity can be measured using TAPPI Test Method T 425 om-01 “Opacity ofPaper (15/d geometry, Illuminant A/2 degrees, 89% Reflectance Backingand Paper Backing)”. The opacity is measured as a percentage. For thepresent invention, the base substrate opacity is greater than 5%,preferably greater than 10%, more preferably greater than 20%, stillmore preferably greater than 30% and most preferably greater than 40%.

A relatively high opacity is desirable as the structured fibrous web,being comprised by an acquisition system of a disposable absorbentarticle, can help in disguising possible staining of the underlyingabsorbent core. Staining of the absorbent core can be due to theabsorption of body fluids such as urine or bowl movement of lowviscosity. The current trend in absorbent articles is to reduce thebasis weight of the different absorbent article components for costsaving reasons. Thus, if a low basis weight topsheet is applied, thetopsheet will likely have lower opacity compared to a high basis weighttopsheet. Also, if an apertured topsheet is applied, the apertures alsoallow to see the underlying layers of the absorbent article, such as theacquisition system and the absorbent core. Therefore, high opacity ofthe structured fibrous web is especially desirable in embodiments,wherein the absorbent article uses a low basis weight topsheet and/or anapertured topsheet. In one embodiment of the present invention, thedisposable absorbent article comprises a topsheet having a basis weightof from 5 g/m² to 25 g/m², more preferably from 8 g/m² to 16 gm².

The base substrate has a characteristic basis weight and acharacteristic density. Basis weight is defined as a fiber/nonwoven massper unit area. For the present invention, the basis weight of the basesubstrate is between 10 g/m² and 200 g/m². The base substrate density isdetermined by dividing the base substrate basis weight by the basesubstrate thickness. For the present invention the density of the basesubstrate is between 14 kg/m³ and 200 kg/m³. The base substrate also hasa base substrate specific volume which is an inverse of the basesubstrate density measured in cubic centimeters per gram.

Base Substrate Modification

In the present invention, the base substrate can be modified to optimizeits fluid dispersion and acquisition properties for use in productswhere fluid management is important. The fluid dispersion properties canbe enhanced by changing the surface energy of the base substrate toincrease hydrophilicity and corresponding wicking properties. Modifyingthe surface energy of the base substrate is optional and is typicallyperformed as the base substrate is made. The fluid acquisitionproperties can be influenced by modifying the structure of the basesubstrate by fiber displacement to introduce a 3D texture whichincreases the thickness or loft and corresponding specific volume of thesubstrate.

Surface Energy

Hydrophilicity of the base substrate relates to the surface energy. Thesurface energy of the base substrate can be modified through topicalsurface treatments, chemical grafting to the surface of the fibers orreactive oxidization of the fiber surfaces via plasma or coronatreatments then further chemical bonding from gas reaction addition.

The surface energy of the base substrate can also be influenced by thepolymeric material used in producing the fibers of the base substrate.The polymeric material can either have inherent hydrophilicity or it canbe rendered hydrophilic through chemical modification of the polymer,fiber surface, and base substrate surface through melt additives orcombination of the polymeric material with other materials that inducehydrophilic behavior. Examples of materials used for polypropylene areIRGASURF® HL560 from Ciba and a PET copolymer from Eastman Chemical,EASTONE® family of polymeric materials for PET.

Surface energy can also be influenced through topical treatments of thefibers. Topical treatment of fiber surfaces generally involvessurfactants that are added in an emulsion via foam, spray, kiss-roll orother suitable technique in a diluted state and then dried. Polymersthat might require a topical treatment are polypropylene or polyesterterephthalate based polymer systems. Other polymers include aliphaticpolyesteramides; aliphatic polyesters; aromatic polyesters includingpolyethylene terephthalates and copolymers, polybutylene terephthalatesand copolymers; polytrimethylene terephthalates and copolymers;polylactic acid and copolymers. A category of materials referred to assoil release polymers (SRP) are also suitable for topical treatment.Soil release polymers are a family of materials that include lowmolecular weight polyester polyether, polyester polyether blockcopolymer and nonionic polyester compounds. Some of these materials canbe added as melt additives, but their preferred usage is as topicaltreatments. Commercial examples of this category of materials areavailable from Clariant as the Texcare™ family of products.

Structured Substrate

The second modification to the base substrate 20 involves mechanicallytreating the base substrate to produce a structured fibrous websubstrate (the terms “structured fibrous web” and “structured substrate”are used interchangeably herein). The structured substrate is defined as(1) a base substrate permanently deformed through fiber rearrangementand fiber separation and breakage producing permanent fiber dislocation(referred to hereinafter as “fiber displacement”) such that thestructured substrate has a thickness value which is higher than that ofthe base substrate and optionally (2) a base substrate modified by overbonding (referred to hereinafter as “over bonding”) to form a compressedregion below the thickness of the base substrate. Fiber displacementprocesses involve permanent mechanical displacement of fibers via rods,pins, buttons, structured screens or belts or other suitable technology.The permanent fiber dislocation provides additional thickness or calipercompared to the base substrate. The additional thickness increasesspecific volume of the substrate and also increases fluid permeabilityof the substrate. The over bonding improves the mechanical properties ofthe base substrate and can enhance the depth of channels in betweendisplaced fiber regions for fluid management.

Fiber Displacement

The base substrate previously described can be processed using theapparatus 150 shown in FIG. 1 to form structured substrate 21, a portionof which is shown in FIGS. 3-6. As shown in FIG. 3, the structuredsubstrate has a first region 2 in the X-Y plane and a plurality ofsecond regions 4 disposed throughout the first region 2. The secondregions 4 comprise displaced fibers 6 forming discontinuities 16 on thesecond surface 14 of the structured substrate 21 and displaced fibers 6having loose ends 18 extending from the first surface 12. As shown inFIG. 4, the displaced fibers 6 extend from a first side 11 of the secondregion 4 and are separated and broken forming loose ends 18 along asecond side 13 opposite the first side 11 proximate to the first surface12. For the present invention, proximate to the first surface 12 meansthe fiber breakage occurs between the first surface 12 and the peak ordistal portion 3 of the displaced fibers, preferably, closer to thefirst surface 12 than to the distal portion 3 of the displaced fibers 6.

The location of the fiber separation or breakage is primary attributedto the non extendable fibers forming the base substrate; however,displaced fiber formation and corresponding fiber breakage is alsoinfluenced by the extent of bonding used in forming the base substrate.A base substrate comprising fully bonded non extensible fibers providesa structure that due to its fiber strength, fiber stiffness, and bondingstrength forms tent like structures at low fiber displacementdeformations, as shown in the micrograph in FIG. 15. Once the fiberdisplacement deformation is extended, substantial fiber breakage isobserved, typically concentrated on one side as shown in the micrographin FIG. 16.

The purpose for creating the displaced fibers 6 having loose ends 18 inFIG. 4 is to increase the structured substrate specific volume over thebase substrate specific volume by creating void volume. For the presentinvention it has been found that creating displaced fibers 6 having atleast 50% and less than 100% loose ends in the second regions produces astructured substrate having an increased caliper and correspondingspecific volume which is sustainable during use. (See Table 6, examples1N5-1N9 provided below) In certain embodiments described further herein,the loose ends 18 of the displaced fibers 6 can be thermally bonded forimproved compression resistance and corresponding sustainability.Displaced fibers 6 having thermally bonded loose ends and a process forproducing the same are discussed more fully below.

As shown in FIG. 5, the displaced fibers 6 in second regions 4 exhibit athickness or caliper which is greater than the first region 2 thickness32 which typically will be the same as the base substrate thickness. Thesize and shape of the second regions 4 having displaced fibers 6 mayvary depending on the technology used. FIG. 5 shows a cross section ofthe structured substrate 21 illustrating displaced fibers 6 in a secondregion 4. Displaced fiber 6 thickness 34 describes the thickness orcaliper of the second region 4 of the structured substrate 21 resultingfrom the displaced fibers 6. As shown, the displaced fiber thickness 34is greater than the first region thickness 32. It is preferred thatdisplaced fiber thickness 34 be at least 110% greater than the firstregion thickness 32, more preferably at least 125% greater, and mostpreferably at least 150% greater than the first region thickness 32. Theaged caliper for displaced fiber thickness 34 is between 0.1 mm and 5mm, preferably between 0.2 mm and 2 mm and most preferably between 0.5mm and 1.5 mm.

The number of second regions 4 having displaced fibers 6 per unit areaof structured substrate 21 can vary as shown in FIG. 3. In general, thearea density need not be uniform across the entire area of structuredsubstrate 21, but second regions 4 can be limited to certain regions ofstructured substrate 21, such as in regions having predetermined shapes,such as lines, stripes, bands, circles, and the like.

As shown in FIG. 3, the total area occupied by the second regions 4 isless than 75%, preferably less than 50% and more preferably less than25% of the total area, but is at least 10%. The size of the secondregions and spacing between second regions 4 can vary. FIG. 3 and FIG. 4show the length 36, width 38 and spacing 37 and 39 between secondregions 4. The spacing 39 in the machine direction between the secondregions 4 shown in FIG. 3 is preferably between 0.1 mm and 1000 mm, morepreferably between 0.5 mm and 100 mm and most preferably between 1 mmand 10 mm. The side to side spacing 37 between the second regions 4 inthe cross machine direction is between 0.2 mm and 16 mm, preferablybetween 0.4 mm and 10 mm, more preferably between 0.8 mm and 7 mm andmost preferably between 1 mm and 5.2 mm.

As shown in FIG. 1, structured substrate 21 can be formed from agenerally planar, two dimensional nonwoven base substrate 20 suppliedfrom a supply roll 152. The base substrate 20 moves in the machinedirection MD by apparatus 150 to a nip 116 formed by intermeshingrollers 104 and 102A which form displaced fibers 6 having loose ends 18.The structured substrate 21 having displaced fibers 6 optionallyproceeds to nip 117 formed between roll 104 and bonding roll 156 whichbonds the loose ends 18 of the displaced fibers 6. From there,structured substrate 22 proceeds to optionally intermeshing rolls 102Band 104 which removes structured substrate 22 from roll 104 andoptionally conveys it to nip 119 formed between roll 102B and bondingroll 158 where over bond regions are formed in structured substrate 23which is eventually taken up on supply roll 160. Although FIG. 1illustrates the sequence of process steps as described, for basesubstrates which are not yet fully bonded it is desirable to reverse theprocess so that bonded regions are formed in the base substrate prior toforming displaced fibers 6. For this embodiment the base substrate 20would be supplied from a supply roll similar to the take up supply roll160 shown in FIG. 1 and moved to a nip 119 formed between roll 102B andbonding roll 158 where the substrate is bonded prior to entering nip 118formed between intermeshing rolls 102B and 104 where displaced fibers 6having loose ends 18 are formed in the second regions 4.

Although FIG. 1 shows base substrate 20 supplied from supply roll 152,the base substrate 20 can be supplied from any other supply means, suchas festooned webs, as is known in the art. In one embodiment, basesubstrate 20 can be supplied directly from a web making apparatus, suchas a nonwoven web-making production line.

As shown in FIG. 1, first surface 12 corresponds to first side of basesubstrate 20, as well as the first side of structured substrate 21.Second surface 14 corresponds to the second side of base substrate 20,as well as the second side of structured substrate 21. In general, theterm “side” is used herein in the common usage of the term to describethe two major surfaces of generally two-dimensional webs, such asnonwovens. Base substrate 20 is a nonwoven web comprising substantiallyrandomly oriented fibers, that is, randomly oriented at least withrespect to the MD and CD. By “substantially randomly oriented” is meantrandom orientation that, due to processing conditions, may exhibit ahigher amount of fibers oriented in the MD than the CD, or vice-versa.For example, in spunbonding and meltblowing processes continuous strandsof fibers are deposited on a support moving in the MD. Despite attemptsto make the orientation of the fibers of the spunbond or meltblownnonwoven web truly “random,” usually a higher percentage of fibers areoriented in the MD as opposed to the CD.

In some embodiments of the present invention it may be desirable topurposely orient a significant percentage of fibers in a predeterminedorientation with respect to the MD in the plane of the web. For example,it may be that, due to tooth spacing and placement on roll 104 (asdiscussed below), it may be desirable to produce a nonwoven web having apredominant fiber orientation at an angle of, for example, 60 degreesoff parallel to the longitudinal axis of the web. Such webs can beproduced by processes that combine lapping webs at the desired angle,and, if desired carding the web into a finished web. A web having a highpercentage of fibers having a predetermined angle can statistically biasmore fibers to be formed into displaced fibers in structured substrate21, as discussed more fully below.

Base substrate 20 can be provided either directly from a web makingprocess or indirectly from a supply roll 152, as shown in FIG. 1. Basesubstrate 20 can be preheated by means known in the art, such as byheating over oil-heated or electrically heated rollers. For example,roll 154 could be heated to pre-heat the base substrate 20 prior to thefiber displacement process.

As shown in FIG. 1, supply roll 152 rotates in the direction indicatedby the arrow as base substrate 20 is moved in the machine direction overroller 154 and to the nip 116 of a first set of counter-rotatingintermeshing rolls 102A and 104. Rolls 102A and 104 are the first set ofintermeshing rollers of apparatus 150. The first set of intermeshingrolls 102A and 104 operate to form displaced fibers and to facilitatefiber breakage in base substrate 20, to make structured substratereferred to herein after as structured substrate 21. Intermeshing rolls102A and 104 are more clearly shown in FIG. 2.

Referring to FIG. 2, there is shown in more detail the portion ofapparatus 150 for making displaced fibers on structured substrate 21 ofthe present invention. This portion of apparatus 150 is shown as niprollers 100 in FIG. 2, and comprises a pair of intermeshing rolls 102and 104 (corresponding to rolls 102A and 104, respectively, in FIG. 1),each rotating about an axis A, the axes A being parallel in the sameplane. Although the apparatus 150 is designed such that base substrate20 remains on roll 104 through a certain angle of rotation, FIG. 2 showsin principle what happens as base substrate 20 goes through nip 116 onapparatus 150 and exits as structured substrate 21 having regions ofdisplaced fibers 6. The intermeshing rolls can be made from metal orplastic. Non-limiting examples of metal rolls would be aluminum orsteel. Non-limiting examples of plastic rolls would be polycarbonate,acrylonitrile butadiene styrene (ABS), and polyphenylene oxide (PPO).The plastics can be filled with metals or inorganic additive materials.

As shown in FIG. 2, roll 102 comprises a plurality of ridges 106 andcorresponding grooves 108 which can extend unbroken about the entirecircumference of roll 102. In some embodiments, depending on what kindof pattern is desired in structured substrate 21, roll 102 (and,likewise, roll 102A) can comprise ridges 106 wherein portions have beenremoved, such as by etching, milling or other machining processes, suchthat some or all of ridges 106 are not circumferentially continuous, buthave breaks or gaps. The breaks or gaps can be arranged to form apattern, including simple geometric patters such as circles or diamonds,but also including complex patterns such as logos and trademarks. In oneembodiment, roll 102 can have teeth, similar to the teeth on roll 104,described more fully below. In this manner, it is possible to havedisplaced fibers 6 on both sides 12, 14 of structured substrate 21.

Roll 104 is similar to roll 102, but rather than having ridges that canextend unbroken about the entire circumference, roll 104 comprises aplurality of rows of circumferentially-extending ridges that have beenmodified to be rows of circumferentially-spaced teeth 110 that extend inspaced relationship about at least a portion of roll 104. The individualrows of teeth 110 of roll 104 are separated by corresponding grooves112. In operation, rolls 102 and 104 intermesh such that the ridges 106of roll 102 extend into the grooves 112 of roll 104 and the teeth 110 ofroll 104 extend into the grooves 108 of roll 102. The intermeshing isshown in greater detail in the cross sectional representation of FIG. 7,discussed below. Both or either of rolls 102 and 104 can be heated bymeans known in the art such as by using hot oil filled rollers orelectrically-heated rollers.

As shown in FIG. 3, structured substrate 21 has a first region 2 definedon both sides of structured substrate 21 by the generally planar,two-dimensional configuration of the base substrate 20, and a pluralityof discrete second regions 4 defined by spaced-apart displaced fibers 6and discontinuities 16 which can result from integral extensions of thefibers of the base substrate 20. The structure of second regions 4 isdifferentiated depending on which side of structured substrate 21 isconsidered. For the embodiment of structured substrate 21 shown in FIG.3, on the side of structured substrate 21 associated with first surface12 of structured substrate 21, each discrete second region 4 cancomprise a plurality of displaced fibers 6 extending outwardly fromfirst surface 12 and having loose ends 18. Displaced fibers 6 comprisefibers having a significant orientation in the Z-direction, and eachdisplaced fiber 6 has a base 5 disposed along a first side 11 of thesecond region 4 proximal to the first surface 12, a loose end 18separated or broken at a second side 13 of the second region 4 oppositethe first side 11 near the first surface 12 and a distal portion 3 at amaximum distance in the Z-direction from the first surface 12. On theside of structured substrate 21 associated with second surface 14,second region 4 comprises discontinuities 16 which are defined by fiberorientation discontinuities 16 on the second surface 14 of structuredsubstrate 21. The discontinuities 16 correspond to the locations whereteeth 110 of roll 104 penetrated base substrate 20.

As used herein, the term “integral” as in “integral extension” when usedof the second regions 4 refers to fibers of the second regions 4 havingoriginated from the fibers of the base substrate 20. Therefore, thebroken fibers 8 of displaced fibers 6, for example, can be plasticallydeformed and/or extended fibers from the base substrate 20, and can be,therefore, integral with first regions 2 of structured substrate 21. Inother words, some, but not all of the fibers have been broken, and suchfibers had been present in base substrate 20 from the beginning. As usedherein, “integral” is to be distinguished from fibers introduced to oradded to a separate precursor web for the purpose of making displacedfibers. While some embodiments of structured substrates 21, 22 and 23 ofthe present invention may utilize such added fibers, in a preferredembodiment, broken fibers 8 of displaced fibers 6 are integral tostructured substrate 21.

It can be appreciated that a suitable base substrate 20 for a structuredsubstrate 21 of the present invention having broken fibers 8 indisplaced fibers 6 should comprise fibers having sufficient fiberimmobility and/or plastic deformation to break and form loose ends 18.Such fibers are shown as loose fiber ends 18 in FIGS. 4 and 5. For thepresent invention, loose fiber ends 18 of displaced fibers 6 aredesirable for producing void space or free volume for collecting fluid.In a preferred embodiment at least 50%, more preferably at least 70% andless than 100% of the fibers urged in the Z-direction are broken fibers8 having loose ends 18.

The second regions 4 can be shaped to form patterns in both the X-Yplane and the Z-plane to target specific volume distributions that canvary in shape, size and distribution.

Representative second region having displaced fibers 6 for theembodiment of structured substrate 21 shown in FIG. 2 is shown in afurther enlarged view in FIGS. 3-6. The representative displaced fibers6 are of the type formed on an elongated tooth 110 on roll 104, suchthat the displaced fibers 6 comprises a plurality of broken fibers 8that are substantially aligned such that the displaced fibers 6 have adistinct longitudinal orientation and a longitudinal axis L. Displacedfibers 6 also have a transverse axis T generally orthogonal tolongitudinal axis L in the MD-CD plane. In the embodiment shown in FIGS.2-6, longitudinal axis L is parallel to the MD. In one embodiment, allthe spaced apart second regions 4 have generally parallel longitudinalaxes L. In preferred embodiments second regions 4 will have alongitudinal orientation, i.e. second regions will have an elongateshape and will not be circular. As shown in FIG. 4, and more clearly inFIGS. 5 and 6, when elongated teeth 110 are utilized on roll 104, onecharacteristic of the broken fibers 8 of displaced fibers 6 in oneembodiment of structured substrate 21 is the predominant directionalalignment of the broken fibers 8. As shown in FIGS. 5 and 6, many ofbroken fibers 8 can have a substantially uniform alignment with respectto transverse axis T when viewed in plan view, such as in FIG. 6. By“broken” fibers 8 is meant that displaced fibers 6 begin on the firstside 11 of second regions 4 and are separated along a second side 13 ofsecond regions 4 opposite the first side 11 in structured substrate 21.

As can be understood with respect to apparatus 150, therefore, displacedfibers 6 of structured substrate 21 are made by mechanically deformingbase substrate 20 that can be described as generally planar and twodimensional. By “planar” and “two dimensional” is meant simply that theweb is flat relative to the finished structured substrate 1 that hasdistinct, out-of-plane, Z-direction three-dimensionality imparted due tothe formation of second regions 4. “Planar” and “two-dimensional” arenot meant to imply any particular flatness, smoothness ordimensionality. As base substrate 20 goes through the nip 116 the teeth110 of roll 104 enter grooves 108 of roll 102A and simultaneously urgefibers out of the plane of base substrate 20 to form second regions 4,including displaced fibers 6 and discontinuities 16. In effect, teeth110 “push” or “punch” through base substrate 20. As the tip of teeth 110push through base substrate 20 the portions of fibers that are orientedpredominantly in the CD and across teeth 110 are urged by the teeth 110out of the plane of base substrate 20 and are stretched, pulled, and/orplastically deformed in the Z-direction, resulting in formation ofsecond region 4, including the broken fibers 8 of displaced fibers 6.Fibers that are predominantly oriented generally parallel to thelongitudinal axis L, i.e., in the machine direction of base substrate20, can be simply spread apart by teeth 110 and remain substantially inthe first region 2 of base substrate 20.

In FIG. 2, the apparatus 100 is shown in one configuration having onepatterned roll, e.g., roll 104, and one non-patterned grooved roll 102.However, in certain embodiments it may be preferable to form nip 116 byuse of two patterned rolls having either the same or differing patterns,in the same or different corresponding regions of the respective rolls.Such an apparatus can produce webs with displaced fibers 6 protrudingfrom both sides of the structured web 21, as well as macro-patternsembossed into the web 21.

The number, spacing, and size of displaced fibers 6 can be varied bychanging the number, spacing, and size of teeth 110 and makingcorresponding dimensional changes as necessary to roll 104 and/or roll102. This variation, together with the variation possible in basesubstrate 20 and the variation in processing, such as line speeds,permits many varied structured webs 21 to be made for many purposes.

From the description of structured web 21, it can be seen that thebroken fibers 8 of displaced fibers 6 can originate and extend fromeither the first surface 12 or the second surface 14 of structuredsubstrate 21. Of course the broken fibers 8 of displaced fibers 6 canalso extend from the interior 19 of structured substrate 21. As shown inFIG. 5, the broken fibers 8 of displaced fibers 6 extend due to havingbeen urged out of the generally two-dimensional plane of base substrate20 (i.e., urged in the “Z -direction” as shown in FIG. 3). In general,the broken fibers 8 or loose ends 18 of the second regions 4 comprisefibers that are integral with and extend from the fibers of the fibrousweb first regions 2.

The extension of broken fibers 8 can be accompanied by a generalreduction in fiber cross sectional dimension (e.g., diameter for roundfibers) due to plastic deformation of the fibers and the effects ofPoisson's ratio. Therefore, portions of the broken fibers 8 of displacedfibers 6 can have an average fiber diameter less than the average fiberdiameter of the fibers of base substrate 20 as well as the fibers offirst regions 2. It has been found that the reduction in fibercross-sectional dimension is greatest intermediate the base 5 and theloose ends 3 of displaced fibers 6. This is believed to be due toportions of fibers at the base 5 and distal portion 3 of displacedfibers 6 are adjacent the tip of teeth 110 of roll 104, described morefully below, such that they are frictionally locked and immobile duringprocessing. In the present invention the fiber cross section reductionis minimal due to the high fiber strength and low fiber elongation.

FIG. 7 shows in cross section a portion of the intermeshing rolls 102(and 102A and 102B, discussed below) and 104 including ridges 106 andteeth 110. As shown teeth 110 have a tooth height TH (note that TH canalso be applied to ridge 106 height; in a preferred embodiment toothheight and ridge height are equal), and a tooth-to-tooth spacing (orridge-to-ridge spacing) referred to as the pitch P. As shown, depth ofengagement, (DOE) E is a measure of the level of intermeshing of rolls102 and 104 and is measured from tip of ridge 106 to tip of tooth 110.The depth of engagement E, tooth height TH, and pitch P can be varied asdesired depending on the properties of base substrate 20 and the desiredcharacteristics of structured substrate 1 of the present invention. Forexample, in general, to obtain broken fibers 8 in displaced fibers 6requires a level of engagement E sufficient to elongate and plasticallydeform the displaced fibers to a point where the fibers break. Also, thegreater the density of second regions 4 desired (second regions 4 perunit area of structured substrate 1), the smaller the pitch should be,and the smaller the tooth length TL and tooth distance TD should be, asdescribed below.

FIG. 8 shows a portion of one embodiment of a roll 104 having aplurality of teeth 110 useful for making a structured substrate 21 orstructured substrate 1 of spunbond nonwoven material from a spunbondnonwoven base substrate 20. An enlarged view of teeth 110 shown in FIG.8 is shown in FIG. 9. In this view of roll 104, teeth 110 have a uniformcircumferential length dimension TL of about 1.25 mm measured generallyfrom the leading edge LE to the trailing edge TE at the tooth tip 111,and are uniformly spaced from one another circumferentially by adistance TD of about 1.5 mm. For making a fibrous structured substrate 1from a base substrate 20, teeth 110 of roll 104 can have a length TLranging from about 0.5 mm to about 3 mm and a spacing TD from about 0.5mm to about 3 mm, a tooth height TH ranging from about 0.5 mm to about10 mm, and a pitch P between about 1 mm (0.040 inches) and 2.54 mm(0.100 inches). Depth of engagement E can be from about 0.5 mm to about5 mm (up to a maximum approaching the tooth height TH). Of course, E, P,TH, TD and TL can each be varied independently of each other to achievea desired size, spacing, and area density of displaced fibers 6 (numberof displaced fibers 6 per unit area of structured substrate 1).

As shown in FIG. 9, each tooth 110 has a tip 111, a leading edge LE anda trailing edge TE. The tooth tip 111 can be rounded to minimize fiberbreakage and is preferably elongated and has a generally longitudinalorientation, corresponding to the longitudinal axes L of second regions4. It is believed that to get the displaced fibers 6 of the structuredsubstrate 1, the LE and TE should be very nearly orthogonal to the localperipheral surface 120 of roll 104. As well, the transition from the tip111 and the LE or TE should be a relatively sharp angle, such as a rightangle, having a sufficiently small radius of curvature such that, in usethe teeth 110 push through base substrate 20 at the LE and TE. Analternative tooth tip 111 can be a flat surface to optimize bonding.

Referring back to FIG. 1, after displaced fibers 6 are formed,structured substrate 21 may travel on rotating roll 104 to nip 117between roll 104 and a first bonding roll 156. Bonding roll 156 canfacilitate a number of bonding techniques. For example, bonding roll 156can be a heated steel roller for imparting thermal energy in nip 117,thereby melt-bonding adjacent fibers of structured web 21 at the distalends (tips) of displaced fibers 6.

In a preferred embodiment, as discussed in the context of a preferredstructured substrate below, bonding roll 156 is a heated roll designedto impart sufficient thermal energy to structured web 21 so as tothermally bond adjacent fibers of the distal ends of displaced fibers 6.Thermal bonding can be by melt-bonding adjacent fibers directly, or bymelting an intermediate thermoplastic agent, such as polyethylenepowder, which in turn, adheres adjacent fibers. Polyethylene powder canbe added to base substrate 20 for such purposes.

First bonding roll 156 can be heated sufficiently to melt or partiallymelt fibers at the distal ends 3 of displaced fibers 6. The amount ofheat or heat capacity necessary in first bonding roll 156 depends on themelt properties of the fibers of displaced fibers 6 and the speed ofrotation of roll 104. The amount of heat necessary in first bonding roll156 also depends on the pressure induced between first bonding roll 156and tips of teeth 110 on roll 104, as well as the degree of meltingdesired at distal ends 3 of displaced fibers 6.

In one embodiment, first bonding roll 156 is a heated steel cylindricalroll, heated to have a surface temperature sufficient to melt-bondadjacent fibers of displaced fibers 6. First bonding roll 156 can beheated by internal electrical resistance heaters, by hot oil, or by anyother means known in the art for making heated rolls. First bonding roll156 can be driven by suitable motors and linkages as known in the art.Likewise, first bonding roll can be mounted on an adjustable supportsuch that nip 117 can be accurately adjusted and set.

FIG. 10 shows a portion of structured substrate 21 after being processedthrough nip 117 to be structured substrate 22, which, without furtherprocessing can be a structured substrate 21 of the present invention.Structured substrate 22 is similar to structured substrate 21 asdescribed earlier, except that the distal ends 3 of displaced fibers 6are bonded, and are preferably thermally melt-bonded such that adjacentfibers are at least partially bonded to form distally-disposedmelt-bonded portions 9. After forming displaced fibers 6 by the processdescribed above, the distal portions 3 of displaced fibers 6 can beheated to thermally join portions of fibers such that adjacent fiberportions are joined to one another to form displaced fibers 6 havingmelt-bonded portions 9, also referred to as “tip bonding”.

The distally-disposed melt-bonded portions 9 can be made by applicationof thermal energy and pressure to the distal portions of displacedfibers 6. The size and mass of the distally-disposed melt-bondedportions 9 can be modified by modifying the amount of heat energyimparted to the distal portions of displaced fibers 6, the line speed ofapparatus 150, and the method of heat application.

In another embodiment, distally-disposed melt-bonded portions 9 can bemade by application of radiant heat. That is, in one embodiment bondingroll 156 can be replaced or supplemented by a radiant heat source, suchthat radiant heat can be directed toward structured substrate 21 at asufficient distance and corresponding sufficient time to cause fiberportions in the distally-disposed portions of displaced fibers 6 tosoften or melt. Radiant heat can be applied by any of known radiantheaters. In one embodiment, radiant heat can be provided by aresistance-heated wire disposed in relation to structured substrate 21such that it is extended in the CD direction at a sufficiently-close,uniformly-spaced distance that as the web is moved in relation to thewire, radiant heat energy at least partially melts the distally-disposedportions of displaced fibers 6. In another embodiment, a heated flatiron, such as a hand-held iron for ironing clothes, can be held adjacentthe distal ends 3 of displaced fibers 6, such that melting is effectedby the iron.

The benefit of processing the structured substrate 22 as described aboveis that the distal ends 3 of displaced fibers 6 can be melted under acertain amount of pressure in nip 117 without compressing or flatteningdisplaced fibers 6. As such, a three-dimensional web can be produced andset, or “locked in” to shape, so to speak by providing for thermalbonding after forming. Moreover, the distally-disposed bonded ormelt-bonded portions 9 can aid in maintaining the lofty structure ofdisplaced fibers 6 and aged caliper of the structured substrate whenstructured substrate 22 is subjected to compression or shearing forces.For example, a structured substrate 22 processed as disclosed above tohave displaced fibers 6 comprising fibers integral with but extendingfrom first region 2 and having distally-disposed melt-bonded portions 9can have improved shape retention after compression due to winding ontoa supply roll and subsequently unwinding. It is believed that by bondingtogether adjacent fibers at distal portions of displaced fibers 6, thefibers experience less random collapse upon compression; that is, theentire structure of displaced fibers 6 tends to move together, therebypermitting better shape retention upon a disordering event such ascompression and/or shear forces associated with rubbing the surface ofthe web.

In an alternate embodiment described in reference to FIG. 1, substrate20 is moved in the machine direction over roller 154 and to the nip 116of the first set of counter-rotating intermeshing rolls 102A and 104where the depth of engagement is between 0.01 inch and 0.15 inch suchthat partial fiber displacement occurs but there is little, if any,fiber breakage. The web then proceeds to nip 117 formed between roll 104and bonding roll 156 where tips of the partial displaced fibers arebonded. After passing through nip 117, the structured substrate 22proceeds to nip 118 formed between roll 104 and 102B where the depth ofengagement is greater than the depth of engagement at nip 116 such thatthe displaced fibers are further displaced forming broken fibers. Thisprocess can result in a larger number of the displaced fibers 6 beingjoined by the melt-bonded portions 9.

Over Bonding

Over bonding refers to melt bonding performed on a substrate that hasbeen previously undergone fiber displacement. Over bonding is anoptional process step. The over bonding can be done in-line, or canalternatively, be done on a separate converting process.

The over bonding relies upon heat and pressure to fuse the filamentstogether in a coherent pattern. A coherent pattern is defined as apattern that is reproducible along the length of the structuredsubstrate so that a repeat pattern can be observed. The over bonding isdone through a pressurized roller nip in which at least one of the rollsis heated, preferably both rolls are heated. If the over bonding is donewhen the base substrate is already heated, then the pressurized rollernip would not need to be heated. Examples of patterns of over bondregions 11 are shown in FIGS. 12 a through 12 f, however, other overbond patterns are possible. FIG. 12 a shows over bond regions 11 forminga continuous pattern in the machine direction. FIG. 12 b showscontinuous over bond regions 11 in both the machine and cross-directionsso that a continuous network of over bonds 11 is formed. This type ofsystem can be produced with a single-step over bonding roll or multipleroll bonding systems. FIG. 12 c shows over bond regions 11 that arediscontinuous in the machine direction. The MD over bond pattern shownin FIG. 12 c could also include over bond regions 11 in the CDconnecting the MD over bond lines in a continuous or non-continuousdesign. FIG. 12 d shows over bond regions 11 forming a wave pattern inthe MD. FIG. 12 e shows over bond regions 11 forming a herringbonepattern while FIG. 12 f shows a wavy herringbone pattern.

The over bond patterns do not need to be evenly distributed and can becontoured to suit a specific application. The total area affected byover bonding is less than 75% of the total area of the fibrous web,preferably less than 50%, more preferably less than 30% and mostpreferably less than 25%, but should be at least 3%.

FIG. 13 illustrates the characteristics of over bonding. The over bondedregion 11 has a thickness property relative to the first regionthickness 32 of the base substrate 20 measured in-between the overbonded regions. The over bonded region 11 has a compressed thickness 42.The over bonded region has a characteristic width 44 on the structuredsubstrate 21 and a spacing 46 between over bond regions.

The first region thickness 32 is preferably between 0.1 mm and 1.5 mm,more preferably between 0.15 mm and 1.3 mm, more preferably between 0.2mm and 1.0 mm and most preferably between 0.25 mm and 0.7 mm. Overbonded region thickness 42 is preferably between 0.01 mm and 0.5 mm,more preferably between 0.02 mm and 0.25 mm, still more preferablybetween 0.03 mm and 0.1 mm and most preferably between 0.05 mm and 0.08mm. The width 44 of the overbonded region 11 is between 0.05 mm and 15mm, more preferably between 0.075 mm and 10 mm, still more preferablybetween 0.1 mm and 7.5 mm and most preferably between 0.2 mm and 5 mm.The spacing 46 between overbonded regions 11 is not required to beuniform in the structured substrate 21, but the extremes will fallwithin the range of 0.2 mm and 16 mm, preferably between 0.4 mm and 10mm, more preferably between 0.8 mm and 7 mm and most preferably between1 mm and 5.2 mm. Spacing 46, width 44 and thickness 42 of the overbonded regions 11 is based on the properties desired for the structuredsubstrate 21 such as tensile strength and fluid handling properties.

FIG. 13 shows that the over bonds 11 having over bond thickness 42 canbe created on one side of the structured substrate 21. FIG. 14 showsthat the over bonds 11 can be on either side of the structured substrate21 depending on the method used to make the structured substrate 21.Over bonds 11 on both sides 12, 14 of the structured substrate 21 may bedesired to create tunnels when the structured substrate is combined withother nonwovens to further aid in the management of fluids. Forinstance, a double sided structured substrate may be used in amulti-layered high volume fluid acquisition system.

Over Bonding Process

Referring to the apparatus in FIG. 1, structured substrate 23 can havebonded portions that are not, or not only, at distally-disposed portionsof displaced fibers 6. For example, by using a mating ridged rollerinstead of a flat, cylindrical roll for bonding roll 156 other portionsof the structured substrate 23 such as at locations on the first surface12 in the first regions 2 between the second regions 4 can be bonded.For instance, continuous lines of melt-bonded material could be made onfirst surface 12 between rows of displaced fibers 6. The continuouslines of melt-bonded material form over bonded regions 11 as previouslydescribed.

In general, while one first bonding roll 156 is illustrated, there maybe more than one bonding roll at this stage of the process, such thatbonding takes place in a series of nips 117 and/or involving differenttypes of bonding rolls 156. Further, rather than being only a bondingroll, similar rolls can be provided to transfer various substances tobase substrate 20 or structured web 21, such as various surfacetreatments to impart functional benefits. Any processes known in the artfor such application of treatments can be utilized.

After passing through nip 117, structured substrate 22 proceeds to nip118 formed between roll 104 and 102B, with roll 102B preferably beingidentical to roll 102A. The purpose of going around roll 102B is toremove structured substrate 22 from roll 104 without disturbing thedisplaced fibers 6 formed thereon. Because roll 102B intermeshes withroll 104 just as roll 102A did, displaced fibers 6 can fit into thegrooves 108 of roll 102B as structured substrate 22 is wrapped aroundroll 102B. After passing through nip 118, structured substrate 22 can betaken up on a supply roll for further processing as structured substrate23 of the present invention. However, in the embodiment shown in FIG. 1,structured substrate 22 is processed through nip 119 between roll 102Band second bonding roll 158. Second bonding roll 158 can be identical indesign to first bonding roll 156. Second bonding roll 158 can providesufficient heat to at least partially melt a portion of the secondsurface 14 of structured substrate 22 to form a plurality ofnon-intersecting, substantially continuous over bond regions 11corresponding to the nip pressures between the tips of ridges 106 ofroll 102B and the generally flat, smooth surface of roll 158.

Second bonding roll 158 can be used as the only bonding step in theprocess (i.e., without first having structured substrate 22 formed bybonding the distal ends of displaced fibers 6). In such a casestructured web 22 would be a structured web 23 with bonded portions onthe second side 14 thereof. However, in general, structured web 23 ispreferably a double over bonded structured web 22 having bonded distalends of displaced fibers 6 (tip bonding) and a plurality ofnon-intersecting, substantially continuous melt-bonded regions on firstside 12 or second side 14 thereon.

Finally, after structured substrate 23 is formed, it can be taken up ona supply roll 160 for storage and further processing as a component inother products.

In an alternate embodiment a second substrate 21A can be added to thestructured substrate 21 using the process shown in FIG. 1A. The secondsubstrate 21A can be a film, a nonwoven or a second base substrate aspreviously described. For this embodiment, base substrate 20 is moved inthe machine direction over roller 154 and to the nip 116 of the firstset of counter-rotating intermeshing rolls 102A and 104 where the fibersare fully displaced forming broken fibers. The web then proceeds to nip117 formed between roll 104 and bonding roll 156 where second substrate21A is introduced and bonded to the distal portions 3 of the displacedfibers 6. After passing through nip 117, the structured substrate 22proceeds to nip 118 formed between rolls 104 and 102B where the depth ofengagement is zero such that rolls 104 and 102B are not engaged, or thedepth of engagement is less than the depth of engagement formed at nip116 between rolls 102A and 104 such that the no additional fiberdisplacement occurs in the structured substrate. Alternatively, for thisembodiment, the depth of engagement at nip 118 can be set such thatdeformation occurs in the second substrate 21A but no additional fiberdisplacement occurs in the structured substrate 22. In other words, thedepth of engagement at nip 118 is still less than the depth ofengagement at nip 116.

Materials

The composition used to form fibers for the base substrate of thepresent invention can include thermoplastic polymeric andnon-thermoplastic polymeric materials. The thermoplastic polymericmaterial must have rheological characteristics suitable for meltspinning. The molecular weight of the polymer must be sufficient toenable entanglement between polymer molecules and yet low enough to bemelt spinnable. For melt spinning, thermoplastic polymers have molecularweights below about 1,000,000 g/mol, preferably from about 5,000 g/molto about 750,000 g/mol, more preferably from about 10,000 g/mol to about500,000 g/mol and even more preferably from about 50,000 g/mol to about400,000 g/mol. Unless specified elsewhere, the molecular weightindicated is the number average molecular weight.

The thermoplastic polymeric materials are able to solidify relativelyrapidly, preferably under extensional flow, and form a thermally stablefiber structure, as typically encountered in known processes such as aspin draw process for staple fibers or a spunbond continuous fiberprocess. Preferred polymeric materials include, but are not limited to,polypropylene and polypropylene copolymers, polyethylene andpolyethylene copolymers, polyester and polyester copolymers, polyamide,polyimide, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol,ethylene vinyl alcohol, polyacrylates, and copolymers thereof andmixtures thereof. Other suitable polymeric materials includethermoplastic starch compositions as described in detail in U.S.publications 2003/0109605A1 and 2003/0091803. Other suitable polymericmaterials include ethylene acrylic acid, polyolefin carboxylic acidcopolymers, and combinations thereof. The polymers described in USpublications U.S. Pat. No. 6,746,766, U.S. Pat. No. 6,818,295, U.S. Pat.No. 6,946,506 and US application 03/0092343. Common thermoplasticpolymer fiber grade materials are preferred, most notably polyesterbased resins, polypropylene based resins, polylactic acid based resin,polyhydroxyalkonoate based resin, and polyethylene based resin andcombination thereof. Most preferred are polyester and polypropylenebased resins.

Nonlimiting examples of thermoplastic polymers suitable for use in thepresent invention include aliphatic polyesteramides; aliphaticpolyesters; aromatic polyesters including polyethylene terephthalates(PET) and copolymer (coPET), polybutylene terephthalates and copolymers;polytrimethylene terephthalates and copolymers; polypropyleneterephthalates and copolymers; polypropylene and propylene copolymers;polyethylene and polyethylene copolymers; aliphatic/aromaticcopolyesters; polycaprolactones; poly(hydroxyalkanoates) includingpoly(hydroxybutyrate-co-hydroxyvalerate),poly(hydroxybutyrate-co-hexanoate), or other higherpoly(hydroxybutyrate-co-alkanoates) as referenced in U.S. Pat. No.5,498,692 to Noda, herein incorporated by reference; polyesters andpolyurethanes derived from aliphatic polyols (i.e., dialkanoylpolymers); polyamides; polyethylene/vinyl alcohol copolymers; lacticacid polymers including lactic acid homopolymers and lactic acidcopolymers; lactide polymers including lactide homopolymers and lactidecopolymers; glycolide polymers including glycolide homopolymers andglycolide copolymers; and mixtures thereof. Preferred are aliphaticpolyesteramides, aliphatic polyesters, aliphatic/aromatic copolyesters,lactic acid polymers, and lactide polymers.

Suitable lactic acid and lactide polymers include those homopolymers andcopolymers of lactic acid and/or lactide which have a weight averagemolecular weight generally ranging from about 10,000 g/mol to about600,000 g/mol, preferably from about 30,000 g/mol to about 400,000g/mol, more preferably from about 50,000 g/mol to about 200,000 g/mol.An example of commercially available polylactic acid polymers includes avariety of polylactic acids that are available from the ChronopolIncorporation located in Golden, Colo., and the polylactides sold underthe tradename EcoPLA®. Examples of suitable commercially availablepolylactic acid are NATUREWORKS from Cargill Dow and LACEA from MitsuiChemical. Preferred is a homopolymer or copolymer of poly lactic acidhaving a melting temperature from about 160° to about 175° C. Modifiedpoly lactic acid and different stereo configurations may also be used,such as poly L-lactic acid and poly D,L-lactic acid with D-isomer levelsup to 75%. Optional racemic combinations of D and L isomers to producehigh melting temperature PLA polymers are also preferred. These highmelting temperature PL polymers are special PLA copolymers (with theunderstanding that the D-isomer and L-isomer are treated as differentstereo monomers) with melting temperatures above 180° C. These highmelting temperatures are achieved by special control of the crystallitedimensions to increase the average melting temperature.

Depending upon the specific polymer used, the process, and the final useof the fiber, more than one polymer may be desired. The polymers of thepresent invention are present in an amount to improve the mechanicalproperties of the fiber, the opacity of the fiber, optimize the fluidinteraction with the fiber, improve the processability of the melt, andimprove attenuation of the fiber. The selection and amount of thepolymer will also determine if the fiber is thermally bondable andaffect the softness and texture of the final product. The fibers of thepresent invention may comprise a single polymer, a blend of polymers, orbe multicomponent fibers comprising more than one polymer. The fibers inthe present invention are thermally bondable.

Multiconstituent blends may be desired. For example, blends ofpolyethylene and polypropylene (referred to hereafter as polymer alloys)can be mixed and spun using this technique. Another example would beblends of polyesters with different viscosities or monomer content.Multicomponent fibers can also be produced that contain differentiablechemical species in each component. Non-limiting examples would includea mixture of 25 melt flow rate (MFR) polypropylene with 50 MFRpolypropylene and 25 MFR homopolymer polypropylene with 25 MFR copolymerof polypropylene with ethylene as a comonomer.

The more preferred polymeric materials have melting temperatures above110° C., more preferably above 130° C., even more preferably above 145°C., still more preferably above 160° C. and most preferably above 200°C. A still further preference for the present invention is polymers withhigh glass transition temperatures. Glass transition temperatures above−10° C. in the end-use fiber form are preferred, more preferably above0° C., still more preferably above 20° C. and most preferably above 50°C. This combination of properties produces fibers that are stable atelevated temperatures. Exemplary examples of materials of this type arepolypropylene, polylactic acid based polymers, and polyesterterephthalate (PET) based polymer systems.

Optional Materials

Optionally, other ingredients may be incorporated into the spinnablecomposition used to form fibers for the base substrate. The optionalmaterials may be used to modify the processability and/or to modifyphysical properties such as opacity, elasticity, tensile strength, wetstrength, and modulus of the final product. Other benefits include, butare not limited to, stability, including oxidative stability,brightness, color, flexibility, resiliency, workability, processingaids, viscosity modifiers, and odor control. Examples of optionalmaterials include, but are not limited to, titanium dioxide, calciumcarbonate, colored pigments, and combinations thereof. Further additivesincluding, but not limited to, inorganic fillers such as the oxides ofmagnesium, aluminum, silicon, and titanium may be added as inexpensivefillers or processing aides. Other suitable inorganic materials include,but are not limited to, hydrous magnesium silicate, titanium dioxide,calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceousearth, mica glass quartz, and ceramics. Additionally, inorganic salts,including, but not limited to, alkali metal salts, alkaline earth metalsalts and phosphate salts may be used.

Optionally, other ingredients may be incorporated into the composition.These optional ingredients may be present in quantities of less thanabout 50%, preferably from about 0.1% to about 20%, and more preferablyfrom about 0.1% to about 12% by weight of the composition. The optionalmaterials may be used to modify the processability and/or to modifyphysical properties such as elasticity, tensile strength and modulus ofthe final product. Other benefits include, but are not limited to,stability including oxidative stability, brightness, flexibility, color,resiliency, workability, processing aids, viscosity modifiers,biodegradability, and odor control. Nonlimiting examples include salts,slip agents, crystallization accelerators or retarders, odor maskingagents, cross-linking agents, emulsifiers, surfactants, cyclodextrins,lubricants, other processing aids, optical brighteners, antioxidants,flame retardants, dyes, pigments, fillers, proteins and their alkalisalts, waxes, tackifying resins, extenders, and mixtures thereof. Slipagents may be used to help reduce the tackiness or coefficient offriction in the fiber. Also, slip agents may be used to improve fiberstability, particularly in high humidity or temperatures. A suitableslip agent is polyethylene. Thermoplastic starch (TPS) may also be addedto the polymeric composition. Especially important are polymer additivesused to reduce static electricity build-up in the production and use ofpolyester thermoplastic materials, particularly PET. Such preferredmaterials are acetaldehyde acid scavengers, ethoxylated sorbitol esters,glycerol esters, alkyl sulphonate, combinations and mixtures thereof andderivative compounded.

Further additives including inorganic fillers such as the oxides ofmagnesium, aluminum, silicon, and titanium may be added as inexpensivefillers or processing aides. Other inorganic materials include hydrousmagnesium silicate, titanium dioxide, calcium carbonate, clay, chalk,boron nitride, limestone, diatomaceous earth, mica glass quartz, andceramics. Additionally, inorganic salts, including alkali metal salts,alkaline earth metal salts, phosphate salts, may be used as processingaides. Other optional materials that modify the water responsiveness ofthe thermoplastic starch blend fiber are stearate based salts, such assodium, magnesium, calcium, and other stearates, as well as rosincomponent, such as gum rosin.

Hydrophilic agents can be added to the polymeric composition. Thehydrophilic agents can be added in standard methods known to thoseskilled in the art. The hydrophilic agents can be low molecular weightpolymeric materials or compounds. The hydrophilic agent can also be apolymeric material with higher molecular weight. The hydrophilic agentcan be present in an amount from 0.01 wt % to 90 wt %, with preferredrange of 0.1 wt % to 50 wt % and a still more preferred range of 0.5 wt% to 10 wt %. The hydrophilic agent can be added when the initial resinis produced at the resin manufacturer, or added as masterbatch in theextruder when the fibers are made. Preferred agents are polyesterpolyether, polyester polyether copolymers and nonionic polyestercompounds for polyester bases polymers. Ethoxylated low and highmolecular weight polyolefinic compounds can also be added.Compatibilizing agents can be added to these materials to aid in betterprocessing for these materials, and to make for a more uniform andhomogenous polymeric compound. One skilled in the art would understandthat using compatibilizing agents can be added in a compounding step toproduce polymer alloys with melt additives not inherently effective withthe base polymer. For example, a base polypropylene resin can becombined with a hydrophilic polyester polyether copolymer through theuse of maleated polypropylene as a compatibilizer agent.

Fibers

The fibers forming the base substrate in the present invention may bemonocomponent or multicomponent. The term “fiber” is defined as asolidified polymer shape with a length to thickness ratio of greaterthan 1,000. The monocomponent fibers of the present invention may alsobe multiconstituent. Constituent, as used herein, is defined as meaningthe chemical species of matter or the material. Multiconstituent fiber,as used herein, is defined to mean a fiber containing more than onechemical species or material. Multiconstituent and alloyed polymers havethe same meaning in the present invention and can be usedinterchangeably. Generally, fibers may be of monocomponent ormulticomponent types. Component, as used herein, is defined as aseparate part of the fiber that has a spatial relationship to anotherpart of the fiber. The term multicomponent, as used herein, is definedas a fiber having more than one separate part in spatial relationship toone another. The term multicomponent includes bicomponent, which isdefined as a fiber having two separate parts in a spatial relationshipto one another. The different components of multicomponent fibers arearranged in substantially distinct regions across the cross-section ofthe fiber and extend continuously along the length of the fiber. Methodsfor making multicomponent fibers are well known in the art.Multicomponent fiber extrusion was well known in the 1960's. DuPont wasa lead technology developer of multicomponent capability, with U.S. Pat.No. 3,244,785 and U.S. Pat. No. 3,704,971 providing a technologydescription of the technology used to make these fibers. “BicomponentFibers” by R. Jeffries from Merrow Publishing in 1971 laid a solidgroundwork for bicomponent technology. More recent publications include“Taylor-Made Polypropylene and Bicomponent Fibers for the NonwovenIndustry,” Tappi Journal December 1991 (p 103) and “Advanced FiberSpinning Technology” edited by Nakajima from Woodhead Publishing.

The nonwoven fabric formed in the present invention may contain multipletypes of monocomponent fibers that are delivered from differentextrusion systems through the same spinneret. The extrusion system, inthis example, is a multicomponent extrusion system that deliversdifferent polymers to separate capillaries. For instance, one extrusionsystem would deliver polyester terephthalate and the other a polyesterterephthalate copolymer such that the copolymer composition melts at adifferent temperatures. In a second example, one extrusion system mightdeliver a polyester terephthalate resin and the other polypropylene. Ina third example, one extrusion system might deliver a polyesterterephthalate resin and the other an additional polyester terephthalateresin that has a molecular weight different from the first polyesterterephthalate resin. The polymer ratios in this system can range from95:5 to 5:95, preferably from 90:10 to 10:90 and 80:20 to 20:80.

Bicomponent and multicomponent fibers may be in a side-by-side,sheath-core, segmented pie, ribbon, islands-in-the-sea configuration, orany combination thereof The sheath may be continuous or non-continuousaround the core. Non-inclusive examples of exemplarily multicomponentfibers are disclosed in U.S. Pat. No. 6,746,766. The ratio of the weightof the sheath to the core is from about 5:95 to about 95:5. The fibersof the present invention may have different geometries that include, butare not limited to; round, elliptical, star shaped, trilobal, multilobalwith 3-8 lobes, rectangular, H-shaped, C-shaped, I-shape, U-shaped andother various eccentricities. Hollow fibers can also be used. Preferredshapes are round, trilobal and H-shaped. The round and trilobal fibershapes can also be hollow.

A “highly attenuated fiber” is defined as a fiber having a high drawdown ratio. The total fiber draw down ratio is defined as the ratio ofthe fiber at its maximum diameter (which is typically resultsimmediately after exiting the capillary) to the final fiber diameter inits end use. The total fiber draw down ratio will be greater than 1.5,preferable greater than 5, more preferably greater than 10, and mostpreferably greater than 12. This is necessary to achieve the tactileproperties and useful mechanical properties.

The fiber “diameter” of the shaped fiber of the present invention isdefined as the diameter of a circle which circumscribes the outerperimeter of the fiber. For a hollow fiber, the diameter is not of thehollow region but of the outer edge of the solid region. For a non-roundfiber, fibers diameters are measured using a circle circumscribed aroundthe outermost points of the lobes or edges of the non-round fiber. Thiscircumscribed circle diameter may be referred to as that fiber'seffective diameter. Preferably, the highly attenuated multicomponentfiber will have an effective fiber diameter of less than 500micrometers. More preferably the effective fiber diameter will be 250micrometer or less, even more preferably 100 micrometers or less, andmost preferably less than 50 micrometers. Fibers commonly used to makenonwovens will have an effective fiber diameter of from about 5micrometers to about 30 micrometers. Fibers in the present inventiontend to be larger than those found in typical spunbond nonwovens. Assuch fibers with effective diameters less than 10 micrometers are not ofuse. Fibers useful in the present invention have an effective diametergreater than about 10 microns, more preferably greater than 15micrometers, and most preferably greater than 20 micrometers. Fiberdiameter is controlled by spinning speed, mass through-put, and blendcomposition. When the fibers in the present invention are made into adiscrete layer, that layer can be combined with additional layers thatmay contain small fibers, even nano-dimension fibers.

The term spunlaid diameter refers to fibers having an effective diametergreater than about 12.5 micrometers up to 50 micrometers. This diameterrange is produced by most standard spunlaid equipment. Micrometers andmicron (μm) mean the same thing and can be used interchangeably.Meltblown diameters are smaller than spunlaid diameters. Typically,meltblown diameters are from about 0.5 to about 12.5 micrometers.Preferable meltblown diameters range from about 1 to about 10micrometers.

Because the diameter of shaped fibers can be hard to determine, thedenier of the fiber is often referenced. Denier is defined as the massof a fiber in grams at 9000 linear meters of length, expressed as dpf(denier per filament). Thus, the inherent density of the fiber is alsofactored in when converting from diameter to denier and visa versa. Forthe present invention, the preferred denier range is greater than 1 dpfand less than 100 dpf. A more preferred denier range is 1.5 dpf to 50dpf and a still more preferred range from 2.0 dpf to 20 dpf, and a mostpreferred range of 4 dpf to 10 dpf. An example of the denier to diameterrelationship for polypropylene is a 1 dpf fiber of polypropylene that issolid round with a density of about 0.900 g/cm³ has a diameter of about12.55 micrometers.

For the present invention, it is desirable for the fibers to havelimited extensibility and exhibit a stiffness to withstand compressiveforces. The fibers of the present invention will have individual fiberbreaking loads of greater than 5 grams per filament. Tensile propertiesof fibers are measured following a procedure generally described by ASTMstandard D 3822-91 or an equivalent test, but the actual test that wasused is fully described below. The tensile modulus (initial modulus asspecified in ASTM standard D 3822-91 unless otherwise specified) shouldbe greater than 0.5 GPa (giga pascals), more preferably greater than 1.5GPa, still more preferably more than 2.0 GPa and most preferably greaterthan 3.0 GPa. The higher tensile modulus will produce stiffer fibersthat provide a sustainable specific volume. Examples will be providedbelow.

The hydrophilicity and hydrophobicity of the fibers can be adjusted inthe present invention. The base resin properties can have hydrophilicproperties via copolymerization (such as the case for certain polyesters(EASTONE from Eastman Chemical, the sulfopolyester family of polymers ingeneral) or polyolefins such as polypropylene or polyethylene) or havematerials added to the base resin to render it hydrophilic. Exemplarilyexamples of additives include CIBA Irgasurf® family of additives. Thefibers in the present invention can also be treated or coated after theyare made to render them hydrophilic. In the present invention, durablehydrophilicity is preferred. Durable hydrophilicity is defined asmaintaining hydrophilic characteristics after more than one fluidinteraction. For example, if the sample being evaluated is tested fordurable hydrophilicity, water can be poured on the sample and wettingobserved. If the sample wets out it is initially hydrophilic. The sampleis then completely rinsed with water and dried. The rinsing is best doneby putting the sample in a large container and agitating for ten secondsand then drying. The sample after drying should also wet out whencontacted again with water.

The fibers of the present invention are thermally stable. Fiber thermalstability is defined as having less than 30% shrinkage in boiling water,more preferably less than 20% shrinkage and most preferably less than10% shrinkage. Some fibers in the present invention will have shrinkageless than 5%. The shrinkage is determined by measuring the fiber lengthbefore and after being placed in boiling water for one minute. Highlyattenuated fibers would enable production of thermally stable fibers.

The fiber shapes used in the base substrate in the present invention mayconsist of solid round, hollow round and various multi-lobal shapedfibers, among other shapes. A mixture of shaped fibers havingcross-sectional shapes that are distinct from one another is defined tobe at least two fibers having cross-sectional shapes that are differentenough to be distinguished when examining a cross-sectional view with ascanning electron microscope. For example, two fibers could be trilobalshape but one trilobal having long legs and the other trilobal havingshort legs. Although not preferred, the shaped fibers could be distinctif one fiber is hollow and another solid even if the overallcross-sectional shape is the same.

The multi-lobal shaped fibers may be solid or hollow. The multi-lobalfibers are defined as having more than one inflection point along theouter surface of the fiber. An inflection point is defined as being achange in the absolute value of the slope of a line drawn perpendicularto the surface of fiber when the fiber is cut perpendicular to the fiberaxis. Shaped fibers also include crescent shaped, oval shaped, squareshaped, diamond shaped, or other suitable shapes.

Solid round fibers have been known to the synthetic fiber industry formany years. These fibers have a substantially optically continuousdistribution of matter across the width of the fiber cross section.These fibers may contain micro voids or internal fibrillation but arerecognized as being substantially continuous. There are no inflectionpoints for the exterior surface of solid round fibers.

The hollow fibers of the present invention, either round or multi-lobalshaped, will have a hollow region. A solid region of the hollow fibersurrounds the hollow region. The perimeter of the hollow region is alsothe inside perimeter of the solid region. The hollow region may be thesame shape as the hollow fiber or the shape of the hollow region can benon-circular or non-concentric. There may be more than one hollow regionin a fiber.

The hollow region is defined as the part of the fiber that does notcontain any material. It may also be described as the void area or emptyspace. The hollow region will comprise from about 2% to about 60% of thefiber. Preferably, the hollow region will comprise from about 5% toabout 40% of the fiber. More preferably, the hollow region comprisesfrom about 5% to about 30% of the fiber and most preferably from about10% to about 30% of the fiber. The percentages are given for a crosssectional region of the hollow fiber (i.e., two dimensional).

The percent of hollow region must be controlled for the presentinvention. The percent hollow region is preferably greater than 2% orthe benefit of the hollow region is not significant. However, the hollowregion is preferably less than 60% or the fiber may collapse. Thedesired percent hollow depends upon the materials used, the end use ofthe fiber, and other fiber characteristics and uses.

The average fiber diameter of two or more shaped fibers havingcross-sectional shapes that are distinct from on another is calculatedby measuring each fiber type's average denier, converting the denier ofeach shaped fiber into the equivalent solid round fiber diameter, addingthe average diameters together of each shaped fiber weighted by theirpercent total fiber content, and dividing by the total number of fibertypes (different shaped fibers). The average fiber denier is alsocalculated by converting the average fiber diameter (or equivalent solidround fiber diameter) through the relationship of the fiber density. Afiber is considered having a different diameter if the average diameteris at least about 10% higher or lower. The two or more shaped fibershaving cross-sectional shapes that are distinct from one another mayhave the same diameter or different diameters. Additionally, the shapedfibers may have the same denier or different denier. In someembodiments, the shaped fibers will have different diameters and thesame denier.

Multi-lobal fibers include, but are not limited to, the most commonlyencountered versions such as trilobal and delta shaped. Other suitableshapes of multi-lobal fibers include triangular, square, star, orelliptical. These fibers are most accurately described as having atleast one slope inflection point. A slope inflection point is defined asthe point along the perimeter of the surface of a fiber where the slopeof the fiber changes. For example, a delta shaped trilobal fiber wouldhave three slope inflection points and a pronounced trilobal fiber wouldhave six slope inflection points. Multilobal fibers in the presentinvention will generally have less than about 50 slope inflectionpoints, and most preferably less than about 20 slope inflection points.The multi-lobal fibers can generally be described as non-circular, andmay be either solid or hollow.

The mono and multiconstituent fibers of the present invention may be inmany different configurations. Constituent, as used herein, is definedas meaning the chemical species of matter or the material. Fibers may beof monocomponent in configuration. Component, as used herein, is definedas a separate part of the fiber that has a spatial relationship toanother part of the fiber.

After the fiber is formed, the fiber may further be treated or thebonded fabric can be treated. A hydrophilic or hydrophobic finish can beadded to adjust the surface energy and chemical nature of the fabric.For example, fibers that are hydrophobic may be treated with wettingagents to facilitate absorption of aqueous liquids. A bonded fabric canalso be treated with a topical solution containing surfactants,pigments, slip agents, salt, or other materials to further adjust thesurface properties of the fiber.

The fibers in the present invention can be crimped, although it ispreferred that they are not crimped. Crimped fibers are generallyproduced in two methods. The first method is mechanical deformation ofthe fiber after it is already spun. Fibers are melt spun, drawn down tothe final filament diameter and mechanically treated, generally throughgears or a stuffer box that imparts either a two dimensional or threedimensional crimp. This method is used in producing most carded staplefibers; however, carded staple fiber fabrics are not preferred becausethe fibers are not continuous and the fabrics produced from crimpedfibers are generally very lofty before the fiber deformation technologyis used. The second method for crimping fibers is to extrudemulticomponent fibers that are capable of crimping in a spunlaidprocess. One of ordinary skill in the art would recognize that a numberof methods of making bicomponent crimped spunbond fibers exists;however, for the present invention, three main techniques are consideredfor making crimped spunlaid nonwovens. The first is crimping that occursin the spinline due to differential polymer crystallization in thespinline, a result of differences in polymer type, polymer molecularweight characteristics (e.g., molecular weight distribution) oradditives content. A second method is differential shrinkage of thefibers after they have been spun into a spunlaid substrate. Forinstance, heating the spunlaid web can cause fibers to shrink due todifferences in crystallinity in the as-spun fibers, for example duringthe thermal bonding process. A third method of causing crimping is tomechanically stretch the fibers or spunlaid web (generally formechanical stretching the web has been bonded together). The mechanicalstretching can expose differences in the stress-strain curve between thetwo polymer components, which can cause crimping.

The last two methods are commonly called latent crimping processesbecause they have to be activated after the fibers are spun. In thepresent invention, there is an order of preference for use of crimpedfibers. Carded staple fiber fabrics can be used, so long as they have abase substrate thickness of less than 1.3 mm. Spunlaid or spunbondfabrics are preferred because they contain continuous filaments, whichcan be crimped, as long as the base substrate thickness or caliper isless than 1.3 mm. For the present invention, the base substrate containsless than 100 wt % crimped fibers, preferably less than 50 wt % crimpedfibers, more preferably less than 20 wt % crimped fibers, morepreferably less than 10 wt % and most preferably 0 wt % crimped fibers.Uncrimped fibers are preferred because the crimping process can reducethe amount of fluids transferred on the surface of the fibers and alsothe crimping can reduce the inherent capillarity of the base substrateby decreasing the specific density of the base substrate.

Short length fibers are defined as fibers having a length of less than50 mm. In the present invention, continuous fibers are preferred overshort cut fibers as they provide two additional benefits. The firstbenefit is that fluids can be transferred greater distances withoutfiber ends, thus providing enhanced capillarity. The second benefit isthat continuous fibers produce base substrates with higher tensilestrengths and stiffness, because the bonded network has continuousmatrix of fibers that collectively are more inter-connected than onecomposed of short length fibers. It is preferred that the base substrateof the present invention contain very few short length fibers,preferably less than 50 wt % short length fibers, more preferably lessthan 20 wt % short length fibers, more preferably less than 10 wt % andmost preferably 0 wt % short length fibers.

The fibers produced for the base substrate in the present invention arepreferably thermally bondable. Thermally bondable in the presentinvention is defined as fibers that soften when they are raised near orabove their peak melting temperature and that stick or fuse togetherunder the influence of at least low applied pressures. For thermalbonding, the total fiber thermoplastic content should be more than 30 wt%, preferably more than 50 wt %, still more preferably more than 70 wt %and most preferably more than 90 wt %.

Spunlaid Process

The fibers forming the base substrate in the present invention arepreferably continuous filaments forming spunlaid fabrics. Spunlaidfabrics are defined as unbonded fabrics having basically no cohesivetensile properties formed from essentially continuous filaments.Continuous filaments are defined as fibers with high length to diameterratios, with a ratio of more than 10,000:1. Continuous filaments in thepresent invention that compose the spunlaid fabric are not staplefibers, short cut fibers or other intentionally made short lengthfibers. The continuous filaments in the present invention are onaverage, more than 100 mm long, preferably more than 200 mm long. Thecontinuous filaments in the present invention are also not crimped,intentionally or unintentionally.

The spunlaid processes in the present invention are made using a highspeed spinning process as disclosed in U.S. Pat. Nos. 3,802,817;5,545,371; 6,548,431 and 5,885,909. In these melt spinning processes,extruders supply molten polymer to melt pumps, which deliver specificvolumes of molten polymer that transfer through a spinpack, composed ofa multiplicity of capillaries formed into fibers, where the fibers arecooled through an air quenching zone and are pneumatically drawn down toreduce their size into highly attenuated fibers to increase fiberstrength through molecular level fiber orientation. The drawn fibers arethen deposited onto a porous belt, often referred to as a forming beltor forming table.

The spunlaid process in the present invention used to make thecontinuous filaments will contain 100 to 10,000 capillaries per meter,preferably 200 to 7,000 capillaries per meter, more preferably 500 to5,000 capillaries per meter, and still more preferably 1,000 to 3,000capillaries per meter. The polymer mass flow rate per capillary in thepresent invention will be greater than 0.3 GHM (grams per hole perminute). The preferred range is from 0.4 GHM to 15 GHM, preferablybetween 0.6 GHM and 10 GHM, still more preferred between 0.8 GHM and 5GHM and the most preferred range from 1 GHM to 4 GHM.

The spunlaid process in the present invention contains a single processstep for making the highly attenuated, uncrimped continuous filaments.Extruded filaments are drawn through a zone of quench air where they arecooled and solidified as they are attenuated. Such spunlaid processesare disclosed in U.S. Pat. No. 3,338,992, U.S. Pat. No. 3,802,817, U.S.Pat. No. 4,233,014 U.S. Pat. No. 5,688,468, U.S. Pat. No. 6,548,431B1,U.S. Pat. No. 6,908,292B2 and US Application 2007/0057414A1. Thetechnology described in EP 1340843B1 and EP 1323852B1 can also be usedto produce the spunlaid nonwovens. The highly attenuated continuousfilaments are directly drawn down from the exit of the polymer from thespinneret to the attenuation device, wherein the continuous filamentdiameter or denier does not change substantially as the spunlaid fabricis formed on the forming table. A preferred spunlaid process in thecurrent invention includes a drawing device that pneumatically draws thefibers between the spinneret exits to the pneumatic drawing deviceenabling fibers to lay down onto the forming belt. The process differsfrom other spunlaid processes that mechanically draw the fibers from thespinneret.

The spunlaid process for the present invention produces, in a singlestep; thermally stable, continuous, uncrimped fibers that have a definedinherent tensile strength, fiber diameter or denier as disclosedearlier. Preferred polymeric materials include, but are not limited to,polypropylene and polypropylene copolymers, polyethylene andpolyethylene copolymers, polyester and polyester copolymers, polyamide,polyimide, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol,ethylene vinyl alcohol, polyacrylates, and copolymers thereof andmixtures thereof. Other suitable polymeric materials includethermoplastic starch compositions as described in detail in U.S.publications 2003/0109605A1 and 2003/0091803. Still other suitablepolymeric materials include ethylene acrylic acid, polyolefin carboxylicacid copolymers, and combinations thereof. The polymers described inU.S. Pat. No. 6,746,766, U.S. Pat. No. 6,818,295, U.S. Pat. No.6,946,506 and US Published Application 03/0092343. Common thermoplasticpolymer fiber grade materials are preferred, most notably polyesterbased resins, polypropylene based resins, polylactic acid based resin,polyhydroxyalkonoate based resin, and polyethylene based resin andcombination thereof. Most preferred are polyester and polypropylenebased resins. Exemplary polyester terephthalate (here after referred toas polyester unless stated otherwise) resins are Eastman F61HC (IV=0.61dl/g), Eastman 9663 (IV=0.80 dl/g), DuPont Crystar 4415 (IV=0.61 gl/g).A suitable copolyester is Eastman 9921 (IV-0.81). The polyesterintrinsic viscosity (IV) range suitable for the present invention rangesfrom 0.3 dl/g to 0.9 dl/g, preferably from 0.45 dl/g to 0.85 dl/g andmore preferably from 0.55 dl/g to 0.82 dl/g. Intrinsic viscosity is ameasure of polymer molecular weight and is well known to those skilledin polymer art. Polyester fibers in the present invention may be alloys,monocomponent and shaped. A preferred embodiment is polyester fibersthat are multilobal, preferably trilobal, that are produced from a 0.61dl/g resin with a denier between 3 dpf and 8 dpf. Although PET is mostcommonly referenced in this invention, other polyester terephthalatepolymers can be used, such as PBT, PTT, PCT.

It has been unexpectedly discovered that a specific combination of resinproperties can be used in a spunbond process to produce a thermallybonded PET nonwoven at high denier. Eastman F61HC PET polymer andEastman 9921 coPET have been found to provide an ideal combination forproducing thermally bondable, yet thermally stable fibers. Theunexpected discovery is that F61HC and 9921 can be extruded throughseparate capillaries in a ratio ranging from 70:30 to 90:10 (F61HC:9921ratio) and the resultant web can be thermally bonded together to producea nonwoven that is thermally stable. Thermally stable in this example isdefined as having less than 10% shrinkage in the MD in boiling waterafter 5 minutes. The thermal stability is achieved through a spinningspeed greater than 4000 meter/minute and producing filament deniersranging from 1 dpf to 10 dpf in both round and shaped fibers. Basisweights ranging from 5 g/m² to 100 g/m² have been produced. Thesefabrics have been produced with thermal point bonding. These types offabrics can be used in a wide range of applications, such as disposableabsorbent articles, dryer sheets, and roof felting. If desired, amultibeam system can be used alone or can have a fine fiber diameterlayer placed in between two spunlaid layers and then bonded together.

An additional preferred embodiment is the use of polypropylene fibersand spunlaid nonwovens. The preferred resin properties for polypropyleneare melt flow rates between 5 MFR (melt flow rate in grams per 10minutes) and 400 MFR, with a preferred range between 10 MFR and 100 MFRand a still more preferred range between 15 MFR and 65 MFR with the mostpreferred range between 23 MFR and 40 MFR. The method used to measureMFR is outlined in ASTM D1238 measured at 230° C. with a mass of 2.16kg.

The nonwoven products produced from the monocomponent and multicomponentfibers will also exhibit certain properties, particularly, strength,flexibility, softness, and absorbency. Measures of strength include dryand/or wet tensile strength. Flexibility is related to stiffness and canattribute to softness. Softness is generally described as aphysiologically perceived attribute which is related to both flexibilityand texture. Absorbency relates to the products' ability to take upfluids as well as the capacity to retain them. Absorbency in the presentinvention does not involve the internal regions of the fiber itself uptaking water, such as is found with pulp fibers, regenerated cellulosefibers (e.g. rayon). Because some thermoplastic polymers inherentlytake-up small amount of water (e.g. polyamides), the water uptake islimited to less than 10 wt %, preferably less than 5 wt % and mostpreferably less than 1 wt %. The absorbency in the present inventionarises from the hydrophilicity of the fibers and nonwoven structure anddepends primarily on the fiber surface area, pore size, and bondingintersections. Capillarity is the general phenomenon used to describethe fluid interaction with the fibrous substrate. The nature ofcapillarity is well understood to those skilled in the art and ispresented in detail in “Nonwovens: Theory, Process, Performance andTesting” by Albin Turbak, Chapter 4.

The spunlaid web forming the base substrate in the present inventionwill have an absorbency uptake or holding capacity (C_(holding)) between1 g/g (gram per gram) to 10 g/g, more preferably between 2 g/g and 8 g/gand most preferably between 3 g/g and 7 g/g. This uptake measurement isdone by weighing a dry sample (in grams) that is 15 cm long in MD and 5cm wide in CD, dry weight is m_(dry) then submerging the sample indistilled water for 30 seconds and then removing the sample from water,suspending it vertically (in MD) for 10 seconds and then weighing thesample again, wet weight is m_(wet). The final wet sample weight(m_(wet)) minus the dry sample weight (m_(dry)) divided by the drysamples weight (m_(dry)) gives the absorbency or holding capacity forthe sample (C_(holding)). i.e.:

$C_{holding}:=\frac{m_{wet} - m_{dry}}{m_{dry}}$

The structured substrates have similar holding capacity.

The spunlaid process in the current invention will produce a spunlaidnonwoven with a desired basis weight. Basis weight is defined as afiber/nonwoven mass per unit area. For the present invention, the basisweight of the base substrate is between 10 g/m² and 200 g/m², with apreferred range between 15 g/m² and 100 g/m², with a more preferredrange between 18 g/m² and 80 g/m² and even a more preferred rangebetween 25 g/m² and 72 g/m². The most preferred range is between 30 g/m²and 62 g/m².

The first step in producing a multiconstituent fiber is the compoundingor mixing step. In the compounding step, the raw materials are heated,typically under shear. The shearing in the presence of heat will resultin a homogeneous melt with proper selection of the composition. The meltis then placed in an extruder where fibers are formed. A collection offibers is combined together using heat, pressure, chemical binder,mechanical entanglement, and combinations thereof resulting in theformation of a nonwoven web. The nonwoven is then modified and assembledinto a base substrate.

The objective of the compounding step is to produce a homogeneous meltcomposition. For multiconstituent blends, the purpose of this step is tomelt blend the thermoplastic polymers materials together where themixing temperature is above the highest melting temperaturethermoplastic component. The optional ingredients can also be added andmixed together. Preferably, the melt composition is homogeneous, meaningthat a uniform distribution is found over a large scale and that nodistinct regions are observed. Compatibilizing agents can be added tocombine materials with poor miscibility, such as when polylactic acid isadded to polypropylene or thermoplastic starch is added topolypropylene.

Twin-screw compounding is well known in the art and is used to preparepolymer alloys or to properly mix together polymers with optionalmaterials. Twin-screw extruders are generally a stand alone process usedbetween the polymer manufacture and the fiber spinning step. In order toreduce cost, the fiber extrusion can begin with twin-screw extruder suchthat the compounding is directly coupled with fiber making. In certaintypes of single screw extruders, good mixing and compatibilization canoccur in-line.

The most preferred mixing device is a multiple mixing zone twin screwextruder with multiple injection points. A twin screw batch mixer or asingle screw extrusion system can also be used. As long as sufficientmixing and heating occurs, the particular equipment used is notcritical.

The present invention utilizes the process of melt spinning. In meltspinning, there is no mass loss in the extrudate. Melt spinning isdifferentiated from other spinning, such as wet or dry spinning fromsolution, where a solvent is being eliminated by volatilizing ordiffusing out of the extrudate resulting in a mass loss.

Spinning will occur at 120° C. to about 350° C., preferably 160° C. toabout 320° C., most preferably from 190° C. to about 300° C. Fiberspinning speeds of greater than 100 meters/minute are required.Preferably, the fiber spinning speed is from about 1,000 to about 10,000meters/minute, more preferably from about 2,000 to about 7,000, and mostpreferably from about 2,500 to about 5,000 meters/minute. The polymercomposition must be spun fast to make strong and thermally stablefibers, as determined by single fiber testing and thermal stability ofthe base substrate or structured substrate.

The homogeneous melt composition can be melt spun into monocomponent ormulticomponent fibers on commercially available melt spinning equipment.The equipment will be chosen based on the desired configuration of themulticomponent fiber. Commercially available melt spinning equipment isavailable from Hills, Inc. located in Melbourne, Fla. An outstandingresource for fiber spinning (monocomponent and multicomponent) is“Advanced Fiber Spinning Technology” by Nakajima from WoodheadPublishing. The temperature for spinning range from about 120° C. toabout 350° C. The processing temperature is determined by the chemicalnature, molecular weights and concentration of each component. Examplesof air attenuation technology are sold commercially by Hill's Inc,Neumag and REICOFIL. An example of technology suitable for the presentinvention is the Reifenhäuser REICOFIL 4 spunlaid process. Thesetechnologies are well known in the nonwoven industry.

Fluid Handling

The structured substrate of the present invention can be used to managefluids. Fluid management is defined as the intentional movement of fluidthrough control of the structured substrate properties. In the presentinvention, fluid management is achieved through two steps. The firststep is engineering the base substrate properties through fiber shape,fiber denier, basis weight, bonding method, and surface energy. Thesecond step involves engineering the void volume generated through fiberdisplacement.

Absorbent Articles

FIG. 23 is a plan view of a diaper 210 according to a certain embodimentof the present invention. The diaper 210 is shown in its flat out,uncontracted state (i.e., without elastic induced contraction) andportions of the diaper 210 are cut away to more clearly show theunderlying structure of the diaper 210. A portion of the diaper 210 thatcontacts a wearer is facing the viewer in FIG. 23. The diaper 210generally may comprise a chassis 212 and an absorbent core 214 disposedin the chassis.

The chassis 212 of the diaper 210 in FIG. 23 may comprise the main bodyof the diaper 210. The chassis 212 may comprise an outer covering 216including a topsheet 218, which may be liquid pervious, and/or abacksheet 220, which may be liquid impervious. The absorbent core 214may be encased between the topsheet 218 and the backsheet 220. Thechassis 212 may also include side panels 222, elasticized leg cuffs 224,and an elastic waist feature 226.

The leg cuffs 224 and the elastic waist feature 226 may each typicallycomprise elastic members 228. One end portion of the diaper 210 may beconfigured as a first waist region 230 of the diaper 210. An oppositeend portion of the diaper 210 may be configured as a second waist region232 of the diaper 210. An intermediate portion of the diaper 210 may beconfigured as a crotch region 234, which extends longitudinally betweenthe first and second waist regions 230 and 232. The waist regions 230and 232 may include elastic elements such that they gather about thewaist of the wearer to provide improved fit and containment (elasticwaist feature 226). The crotch region 34 is that portion of the diaper210 which, when the diaper 210 is worn, is generally positioned betweenthe wearer's legs.

The diaper 210 is depicted in FIG. 23 with its longitudinal axis 236 andits transverse axis 238. The periphery 240 of the diaper 210 is definedby the outer edges of the diaper 210 in which the longitudinal edges 242run generally parallel to the longitudinal axis 236 of the diaper 210and the end edges 244 run between the longitudinal edges 242 generallyparallel to the transverse axis 238 of the diaper 210. The chassis 212may also comprise a fastening system, which may include at least onefastening member 246 and at least one stored landing zone 248.

The diaper 220 may also include such other features as are known in theart including front and rear ear panels, waist cap features, elasticsand the like to provide better fit, containment and aestheticcharacteristics. Such additional features are well known in the art andare e.g., described in U.S. Pat. No. 3,860,003 and U.S. Pat. No.5,151,092.

In order to keep the diaper 210 in place about the wearer, at least aportion of the first waist region 230 may be attached by the fasteningmember 246 to at least a portion of the second waist region 232 to formleg opening(s) and an article waist. When fastened, the fastening systemcarries a tensile load around the article waist. The fastening systemmay allow an article user to hold one element of the fastening system,such as the fastening member 246, and connect the first waist region 230to the second waist region 232 in at least two places. This may beachieved through manipulation of bond strengths between the fasteningdevice elements.

According to certain embodiments, the diaper 210 may be provided with are-closable fastening system or may alternatively be provided in theform of a pant-type diaper. When the absorbent article is a diaper, itmay comprise a re-closable fastening system joined to the chassis forsecuring the diaper to a wearer. When the absorbent article is apant-type diaper, the article may comprise at least two side panelsjoined to the chassis and to each other to form a pant. The fasteningsystem and any component thereof may include any material suitable forsuch a use, including but not limited to plastics, films, foams,nonwoven, woven, paper, laminates, fiber reinforced plastics and thelike, or combinations thereof. In certain embodiments, the materialsmaking up the fastening device may be flexible. The flexibility mayallow the fastening system to conform to the shape of the body and thus,reduce the likelihood that the fastening system will irritate or injurethe wearer's skin.

For unitary absorbent articles, the chassis 212 and absorbent core 214may form the main structure of the diaper 210 with other features addedto form the composite diaper structure. While the topsheet 218, thebacksheet 220, and the absorbent core 214 may be assembled in a varietyof well-known configurations, preferred diaper configurations aredescribed generally in U.S. Pat. No. 5,554,145 entitled “AbsorbentArticle With Multiple Zone Structural Elastic-Like Film Web ExtensibleWaist Feature” issued to Roe et al., on Sep. 10, 1996; U.S. Pat. No.5,569,234 entitled “Disposable Pull-On Pant” issued to Buell et al. onOct. 29, 1996; and U.S. Pat. No. 6,004,306 entitled “Absorbent ArticleWith Multi-Directional Extensible Side Panels” issued to Robles et al.on Dec. 21, 1999.

The topsheet 218 in FIG. 23 may be fully or partially elasticized or maybe foreshortened to provide a void space between the topsheet 218 andthe absorbent core 214. Exemplary structures including elasticized orforeshortened topsheets are described in more detail in U.S. Pat. No.5,037,416 entitled “Disposable Absorbent Article Having ElasticallyExtensible Topsheet” issued to Allen et al., on Aug. 6, 1991; and U.S.Pat. No. 5,269,775 entitled “Trisection Topsheets for DisposableAbsorbent Articles and Disposable Absorbent Articles Having SuchTrisection Topsheets” issued to Freeland et al. on Dec. 14, 1993.

The backsheet 226 may be joined with the topsheet 218. The backsheet 220may prevent the exudates absorbed by the absorbent core 214 andcontained within the diaper 210 from soiling other external articlesthat may contact the diaper 210, such as bed sheets and undergarments.In certain embodiments, the backsheet 226 may be substantiallyimpervious to liquids (e.g., urine) and comprise a laminate of anonwoven and a thin plastic film such as a thermoplastic film having athickness of about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).Suitable backsheet films include those manufactured by TredegarIndustries Inc. of Terre Haute, Ind. and sold under the trade namesX15306, X10962, and X10964. Other suitable backsheet materials mayinclude breathable materials that permit vapors to escape from thediaper 210 while still preventing liquid exudates from passing throughthe backsheet 210. Exemplary breathable materials may include materialssuch as woven webs, nonwoven webs, composite materials such asfilm-coated nonwoven webs, and microporous films such as manufactured byMitsui Toatsu Co., of Japan under the designation ESPOIR NO and by EXXONChemical Co., of Bay City, Tex., under the designation EXXAIRE. Suitablebreathable composite materials comprising polymer blends are availablefrom Clopay Corporation, Cincinnati, Ohio under the name HYTREL blendP18-3097. Such breathable composite materials are described in greaterdetail in PCT Application No. WO 95/16746, published on Jun. 22, 1995 inthe name of E. I. DuPont. Other breathable backsheets including nonwovenwebs and apertured formed films are described in U.S. Pat. No. 5,571,096issued to Dobrin et al. on Nov. 5, 1996.

Taking a cross section of FIG. 23 taken along the sectional line 2-2 ofFIG. 23 and starting from the wearer facing side, the diaper 210 maycomprise the topsheet 218, the components of the absorbent core 214, andthe backsheet 220. Diaper 210 also comprises an acquisition system 250disposed between the liquid permeable topsheet 218 and a wearer facingside of the absorbent core 214. The acquisition system 250 may be indirect contact with the absorbent core.

The acquisition system 250 comprises the fibrous web of the presentinvention. It is desirable for the present invention, that the absorbentarticles as a whole are relatively thin. This results in less storagecapacity and less shelf space being needed. Also, thinner absorbentarticles have found to be more appealing to many consumers. In order tofacilitate a thin absorbent article, the acquisition system also shouldbe as thin as possible. However, thinner web materials often have lowertemporary fluid holding capacity. Apart from being thin, the acquisitionsystem should also be able to acquire fluid rapidly, to avoid leakage ofthe absorbent article due to free fluid on the topsheet. Also theacquisition system of the present invention should have good wickingcapability, to allow for fluid transport towards the front and backwaist region of the article. Thereby, it is possible to make moreefficient use of the absorbent material comprised by the absorbent core.Also, increased liquid storage towards the front and back waist regionenables absorbent articles with reduced bulk in the crotch region alsowhen wet.

The fibrous web of the present invention may be used in the acquisitionsystem with the second surface facing towards the topsheet. In theseembodiments, the topsheet facing surface of the first region createsvoid volume that serves to temporarily hold liquid discharged into theabsorbent article. I.e. not only the fibrous web itself but also thearea immediately above the surface between the discontinuities of thefibrous web serves to hold the fluid. The discontinuities formed by thesecond regions and facing towards the topsheet serve as raised areas tomaintain the distance between the topsheet and the first region of thefibrous web. The loose ends of the discontinuities formed by the secondregions create a relatively open structure in the fibrous web, whereliquid can readily and quickly enter into the fibrous web and into theabsorbent core underneath the fibrous web or into additional lowerlayers of the acquisition system (in embodiments having additionalacquisition system layers).

Alternatively, the fibrous web of the present invention may be used inthe acquisition system with the first surface facing towards thetopsheet. In these embodiments, the void volume inside thediscontinuities serves to quickly acquire and temporarily hold fluid.The liquid can spread out to other areas of the fibrous web and to theabsorbent core underneath the fibrous web especially through the looseends formed by the displaced fibers.

In absorbent articles with absorbent cores having high amounts ofabsorbent polymer material, initial fluid absorption is often slowercompared to absorbent cores having a certain amount of airfelt. In theseabsorbent articles it is especially important that the acquisitionsystem is able to acquire and temporarily hold fluid. Also, absorbentcores with high amount of absorbent polymer material typically enable tomake thin absorbent articles which are further supported by acquisitionsystems using the thin structured fibrous webs of the present invention.

Also, it is desirable to provide an acquisition system which enablesvertical wicking of liquid which is faster than vertical wicking withinabsorbent cores having high amounts of absorbent polymer material.

The acquisition system 250 may consist only of the fibrous web of thepresent invention. However, the fibrous web may be a laminate, whereinthe different layers of the laminate have been laminated to each otherbefore the fibrous web undergoes the fiber displacement describedherein.

Alternatively, the acquisition system may comprise the fibrous web ofthe present invention as an upper acquisition layer 252 facing towardsthe wearer's skin and a different, lower acquisition 254 layer facingthe garment of the wearer. According to a certain embodiment, theacquisition system 250 may function to receive a surge of liquid, suchas a gush of urine. In other words, the acquisition system 250 may serveas a temporary reservoir for liquid until the absorbent core 214 canabsorb the liquid.

In a certain embodiment, the acquisition system 250 may comprisechemically cross-linked cellulosic fibers. Such cross-linked cellulosicfibers may have desirable absorbency properties. Exemplary chemicallycross-linked cellulosic fibers are disclosed in U.S. Pat. No. 5,137,537.In certain embodiments, the chemically cross-linked cellulosic fibersare cross-linked with between about 0.5 mole % and about 10.0 mole % ofa C₂ to C₉ polycarboxylic cross-linking agent or between about 1.5 mole% and about 6.0 mole % of a C₂ to C₉ polycarboxylic cross-linking agentbased on glucose unit. Citric acid is an exemplary cross-linking agent.In other embodiments, polyacrylic acids may be used. Further, accordingto certain embodiments, the cross-linked cellulosic fibers have a waterretention value of about 25 to about 60, or about 28 to about 50, orabout 30 to about 45. A method for determining water retention value isdisclosed in U.S. Pat. No. 5,137,537. According to certain embodiments,the cross-linked cellulosic fibers may be crimped, twisted, or curled,or a combination thereof including crimped, twisted, and curled.

In a certain embodiment, the lower acquisition layer 254 may consist ofor may comprise a non-woven, which may be hydrophilic. Further,according to a certain embodiment, the lower acquisition layer 254 maycomprise the chemically cross-linked cellulosic fibers, which may or maynot form part of a nonwoven material. Further, according to anembodiment, the lower acquisition layer 254 may comprise the chemicallycross-linked cellulosic fibers mixed with other fibers such as naturalor synthetic polymeric fibers. According to exemplary embodiments, suchother natural or synthetic polymeric fibers may include high surfacearea fibers, thermoplastic binding fibers, polyethylene fibers,polypropylene fibers, PET fibers, rayon fibers, lyocell fibers, andmixtures thereof. According to a particular embodiment, the loweracquisition layer 254 has a total dry weight, the cross-linkedcellulosic fibers are present on a dry weight basis in the upperacquisition layer in an amount from about 30% to about 95% by weight ofthe lower acquisition layer 254, and the other natural or syntheticpolymeric fibers are present on a dry weight basis in the loweracquisition layer 254 in an amount from about 70% to about 5% by weightof the lower acquisition layer 254. According to another embodiment, thecross-linked cellulosic fibers are present on a dry weight basis in thefirst acquisition layer in an amount from about 80% to about 90% byweight of the lower acquisition layer 254, and the other natural orsynthetic polymeric fibers are present on a dry weight basis in thelower acquisition layer 254 in an amount from about 20% to about 10% byweight of the lower acquisition layer 254.

According to a certain embodiment, the lower acquisition layer 254desirably has a high fluid uptake capability. Fluid uptake is measuredin grams of absorbed fluid per gram of absorbent material and isexpressed by the value of “maximum uptake.” A high fluid uptakecorresponds therefore to a high capacity of the material and isbeneficial, because it ensures the complete acquisition of fluids to beabsorbed by an acquisition material. According to exemplary embodiments,the lower acquisition layer 254 has a maximum uptake of about 10 g/g.

Notably, the fibrous webs of the present invention may also be useful inother parts of an absorbent article. For example, topsheets andabsorbent core layers comprising permanently hydrophilic non-wovens asdescribed above have been found to work well.

The absorbent core 214 may comprise any absorbent material which isgenerally compressible, conformable, non-irritating to the wearer'sskin, and capable of absorbing and retaining urine, such as comminutedwood pulp, creped cellulose wadding; melt blown polymers, includingcoform; chemically stiffened, modified or cross-linked cellulosicfibers; tissue, including tissue wraps and tissue laminates; absorbentfoams; absorbent sponges; absorbent polymer material or any other knownabsorbent material or combinations of materials. The absorbent materialmay be at least partially surrounded by a nonwoven fabric, oftenreferred to as core wrap. The core wrap may consist of an upper layertowards the body-facing surface of the absorbent article and of a lowerlayer towards the garment-facing side of the absorbent article. The twolayers may be continuously or intermittently bonded to each other aroundtheir perimeters. The upper and lower layer may be made of the samenonwoven fabric or may be made of different nonwoven fabric, i.e. theupper layer may be fluid pervious whereas the lower layer may be fluidimpervious. The core wrap may also consist of a single nonwoven fabric,which envelops the absorbent material. It is preferred that theabsorbent cores comprises more than 80% of absorbent polymer material byweight of absorbent material (i.e., excluding the core wrap, ifpresent), more preferably more than 90%. The absorbent core may even befree of airfelt, i.e., 100% absorbent polymer material. The absorbentpolymer material is preferably absorbent particulate polymer material.

The following base substrates were produced at Hills Inc on a 0.5 m widespunbond line. The specifics are mentioned in each example. Measuredproperties of the materials produced in Examples 1, 2, 4, and 7 areproduced in the tables provided below.

EXAMPLE 1

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 9921 coPET. The spunbond fabrics were producedusing a pronounced trilobal spinneret that had 1.125 mm length and 0.15mm width with a round end point. The hydraulic length-to-diameter ratiowas 2.2:1. The spinpack had 250 capillaries of which 25 extruded thecoPET resin and 225 extruded the PET resin. The beam temperature usedwas 285° C. The spinning distance was 33 inches and the forming distancewas 34 inches. Different distances could be used in this and subsequentexamples, but distance indicated provided the best results. Theremainder of the relevant process data is included in Table 1-3.

COMPARATIVE EXAMPLE 1

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 20110. The spunbond fabrics were producedusing a pronounced trilobal spinneret that had 1.125 mm length and 0.15mm width with a round end point. The hydraulic length-to-diameter ratiowas 2.2:1. The spinpack had 250 capillaries of which 25 extruded thecoPET resin and 225 extruded the PET resin. The beam temperature usedwas 285° C. The spinning distance was 33 inches and the forming distancewas 34 inches. It was difficult to produce thermally stable spunbondnonwovens with this polymer combination. The coPET fibers were notthermally stable and caused the entire fiber structure to shrink whenheated above 100° C. The MD fabric shrinkage was 20%.

EXAMPLE 2

Spunbond fabrics were produced composed of 100 wt % Eastman F61HC PET.The spunbond fabrics were produced using a pronounced trilobal spinneretthat had 1.125 mm length and 0.15 mm width with a round end point. Thehydraulic length-to-diameter ratio was 2.2:1. The spinpack had 250capillaries. The beam temperature used was 285° C. The spinning distancewas 33 inches and the forming distance was 34 inches. The remainder ofthe relevant process data is included in Table 1-3.

EXAMPLE 3

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 9921 coPET. The spunbond fabrics were producedusing a standard trilobal spinneret that had 0.55 mm length and 0.127 mmwidth with a round end point with radius 0.18 mm. The hydrauliclength-to-diameter ratio was 2.2:1. The spinpack had 250 capillaries ofwhich 25 extruded the coPET resin and 225 extruded the PET resin. Thebeam temperature used was 285° C. The spinning distance was 33 inchesand the forming distance was 34 inches. The remainder of the relevantprocess data is included in Table 4-6.

COMPARATIVE EXAMPLE 2

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 20110. The spunbond fabrics were producedusing a standard trilobal spinneret that had 0.55 mm length and 0.127 mmwidth with a round end point with radius 0.18 mm. The hydrauliclength-to-diameter ratio 2.2:1. The spinpack had 250 capillaries ofwhich 25 extruded the coPET resin and 225 extruded the PET resin. Thebeam temperature used was 285° C. The spinning distance was 33 inchesand the forming distance was 34 inches. It was difficult to producethermally stable spunbond nonwovens with this polymer combination. ThecoPET fibers were not thermally stable and caused the entire fiberstructure to shrink when heated above 100° C. The MD fabric shrinkagewas 20%.

EXAMPLE 4

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 9921 coPET. The spunbond fabrics were producedusing a solid round spinneret with capillary exit diameter of 0.35 mmand length-to-diameter ratio 4:1. The spinpack had 250 capillaries ofwhich 25 extruded the coPET resin and 225 extruded the PET resin. Thebeam temperature used was 285° C. The spinning distance was 33 inchesand the forming distance was 34 inches. The remainder of the relevantprocess data is included in Table 7-9.

COMPARATIVE EXAMPLE 3

Spunbond fabrics were produced composed of 90 wt % Eastman F61HC PETresin and 10 wt % Eastman 20110. The spunbond fabrics were producedusing a solid round spinneret with capillary exit diameter of 0.35 mmand length-to-diameter ratio 4:1. The spinpack had 250 capillaries ofwhich 25 extruded the coPET resin and 225 extruded the PET resin. Thebeam temperature used was 285° C. The spinning distance was 33 inchesand the forming distance was 34 inches. It was difficult to producethermally stable spunbond nonwovens with this polymer combination. ThecoPET fibers were not thermally stable and caused the entire fiberstructure to shrink when heated above 100° C. The MD fabric shrinkagewas 20%.

Sample Description: The following information provides sampledescription nomenclature used to identify the examples in the tables ofdata provided below.

-   -   The first number references the example number in which it was        produced.    -   The letter following the number is to designate a sample        produced under a different condition in the example description,        which is described broadly. This letter and number combination        specifies production of a base substrate.    -   A number following the letter designates production of a        structured substrate, which is described in the patent.        Different numbers indicate different conditions used to produce        the structured substrate.        There are two reference samples included in the present        invention to compare the base substrate and structured substrate        samples vs carded resin bonded samples.    -   43 g/m²—Consisting of 30% styrene butadiene latex binder and 70%        of a fiber mix. The fiber mix contains a 40:60 mixture of 6 den        solid round PET fibers and 9 den solid round PET fibers        respectively.    -   60 g/m²—Consisting of 30% (carboxylated) styrene butadiene latex        binder and 70% of a fiber mix. The fiber mix contains a 50:50        mixture of 6 den solid round PET fibers and 9 den hollow spiral        PET fibers (25-40% hollow) respectively.        If samples in any of the methods being disclosed have been        previously aged or has been removed from a product, they should        be stored at 23±2° C. and at 50±2% relative humidity for 24        hours with no compression, prior to any of the testing        protocols. The samples after this aging would be referred to as        “as-produced”.        Definitions and Test Method for Properties in Invention: The        test methods for properties in the property tables are listed        below. Unless specified otherwise, all tests are carried out at        about 23±2° C. and at 50±2% relative humidity. Unless specified        explicitly, the specific synthetic urine used is made with 0.9%        (by weight) saline (NaCL) solution made with deinonized water.    -   Mass Throughput: Measures the polymer flow rate per capillary,        measured in grams per hole per minute (GHM) and is calculated        based on polymer melt density, polymer melt pump displacement        per revolution and number of capillaries fed by the melt pump.    -   Shape: Designates the fiber shape based on the capillary        geometry listed in the Example Designation.    -   Actual Basis Weight: The preferred basis weight is measured by        cutting out at least ten 7500 mm² (50 mm wide by 150 mm long        sample size) sample areas at random from the sample and weighing        them to within ±1 mg, then averaging the mass by the total        number of samples weighed. Basis Weight units are in grams per        square meter (g/m²). If 7500 mm square area cannot be used for        basis weight measurement, then the sample size can be reduced        down to 2000 mm², (for example 100 mm by 20 mm sample size or 50        mm by 40 mm sample size), but the number of samples should be        increased to at least 20 measurements. The actual basis weight        is determined by dividing the average mass by the sample area        and making sure the units are in grams per square meter.    -   Fabric Thickness: Thickness is also referred to as caliper and        the two words are used interchangeably. Fabric thickness and        fresh caliper refer to the caliper without any aging conditions.        The test conditions for as-produced caliper are measured at 0.5        kPa and at least five measurements are averaged. A typical        testing device is a Thwing Albert ProGage system. The diameter        of the foot is between 50 mm to 60 mm. The dwell time is 2        seconds for each measurement. The sample must be stored at        23±2° C. and at 50±2% relative humidity for 24 hours with no        compression, then subjected to the fabric thickness measurement.        The preference is to make measurements on the base substrate        before modification, however, if this material is not available        an alternative method can be used. For a structured substrate,        the thickness of the first regions in between the second regions        (displaced fiber regions) can be determined by using a        electronic thickness gauge (for instance available from        McMaster-Carr catalog as Mitutoyo No 547-500). These electronic        thickness gauges can have the tips changed to measure very small        areas. These devises have a preloaded spring for making the        measurement and vary by brand. For example, a blade shaped tip        can be used that is 6.6 mm long and 1 mm wide. Flat round tips        can also be inserted that measure area down below 1.5 mm in        diameter. For measuring on the structured substrate, these tips        need to be inserted between the structured regions to measure        the as-produced fabric thickness. The pressure used in the        measurement technique cannot be carefully controlled using this        technique, with the applied pressure being generally higher than        0.5 kPa.    -   Aged Caliper: This refers to the sample caliper after it has        been aged at 40° C. under 35 kPa pressure for 15 hours and then        relaxed at 23±2° C. and at 50±2% relative humidity for 24 hours        with no compression. This can also be called the caliper        recovery. The aged caliper is measured under a pressure of 2.1        kPA. A typical testing device is a Thwing Albert ProGage system.        The diameter of the foot is between 50 mm to 60 mm. The dwell        time is 2 seconds for each measurement. All samples are stored        at 23±2° C. and at 50±2% relative humidity for 24 hours with no        compression, and then subjected to the aged caliper test.    -   Mod Ratio: The “Mod Ratio” or modification ratio is used to        compensate for additional surface area geometry of non-round        fibers. The modification ratio is determined by measuring the        longest continuous straight line distance in the cross section        of the fiber perpendicular to its longest axis, and dividing by        the width of the fiber at 50% of that distance. For some complex        fiber shapes, it may be difficult to easily determine the        modification ratio. FIG. 19 a-19 c provide examples of shaped        fiber configurations. The “A” designation is the long axis        dimension and the “B” designation is the width dimension. The        ratio is determined by dividing the short dimension into the        long dimension. These units are measured directly via        microscopy.    -   Actual Denier: Actual denier is the measured denier of the fiber        for a given example. Denier is defined as the mass of a fiber in        grams at 9000 linear meters of length. Thus the inherent density        of the fiber is also factored in for the calculation of denier        when comparing fibers from different polymers, expressed as dpf        (denier per filament), so a 2 dpf PP fiber and a 2 dpf PET fiber        will have different fiber diameters. An example of the denier to        diameter relationship for polypropylene is a 1 dpf fiber of        polypropylene that is solid round with a density of about 0.900        g/cm³ has a diameter of about 12.55 micrometers. The density of        PET fibers in the present invention are taken to be 1.4 g/cm³        (grams per cubic centimeter) for denier calculations. For those        skilled in the art, converting from solid round fiber diameter        to denier for PP and PET fibers is routine.    -   Equivalent Solid Round Fiber Diameter: The equivalent solid        round fiber diameter is used for calculating the modulus of        fibers for fiber property measurements for non-round or hollow        shaped fibers. The equivalent solid round fiber diameter is        determined from the actual denier of the fiber. The actual        denier of the non-round fiber is converted into an equivalent        solid round fiber diameter by taking the actual fiber denier and        calculating the diameter of the filament with the assumption it        was solid round. This conversion is important for determining        the modulus of a single fiber for a non-round fiber        cross-section.    -   Tensile Properties of the Nonwoven Fabrics: The tensile        properties of base substrates and structured substrates were all        measured the same way. The gauge width is 50 mm, gauge length is        100 mm and the extension rate is 100 mm/min. The values reported        are for strength and elongation at peak, unless stated        otherwise. Separate measurements are made for the MD and CD        properties. The typical units are Newton (N) per centimeter        (N/cm). The values presented are the average of at least five        measurements. The perforce load is 0.2 N. The samples should be        stored at 23±2° C. and at 50±2% relative humidity for 24 hours        with no compression, then tested at 23±2° C. and at 50±2%. The        tensile strength as reported here is the peak tensile strength        in the stress-strain curve. The elongation at tensile peak is        the percent elongation at which the tensile peak is recorded.    -   MD/CD Ratio: Is defined as the MD tensile strength divided by        the CD tensile strength. The MD/CD ratio is a method used for        comparing the relative fiber orientation in a nonwoven fibrous        substrate.    -   Fiber Perimeter: Was directly measured via microscopy and is the        perimeter of a typical fiber in the nonwoven, expressed in        micrometers. The values presented are the average of at least        five measurements.    -   Opacity: Opacity is a measurement of the relative amount of        light that passes through the base substrate. The characteristic        opacity depends, amongst others, on the number, size, type and        shape of fibers present in a given location that is measured.        For the present invention, the base substrate opacity is        preferably greater than 5%, more preferably greater than 10%,        more preferably greater than 20%, still more preferably greater        than 30% and most preferably greater than 40%. Opacity is        measured using TAPPI Test Method T 425 om-01 “Opacity of Paper        (15/d geometry, Illuminant A/2 degrees, 89% Reflectance Backing        and Paper Backing)”. The opacity is measured as a percentage.    -   Base Substrate Density: The base substrate density is determined        by dividing the actual basis weight of the sample by the aged        caliper of the sample, converting into the same units and        reporting as grams per cubic meter.    -   Base Substrate Specific Volume: The base substrate specific        volume is the inverse of base substrate density in units of        cubic centimeters per gram.    -   Line Speed: The line speed is the linear machine direction speed        at which the sample was produced.    -   Bonding Temperature: The bonding temperature is the temperature        at which the spunbond sample was bonded together. Bonding        temperature includes two temperatures. The first temperature is        the temperature of the engraved or patterned roll and the second        is the temperature of the smooth roll. Unless specified        otherwise, the bonding area was 18% and the calendar linear        pressure was 400 pounds per linear inch.    -   Surfactant Addition to Invention Samples: Refers to the material        used for treating the base substrate and structured substrates        to render them hydrophilic. In the present invention the same        surfactant was used for all samples. The surfactant was a        Procter & Gamble development grade material with code DP-988A.        The material is a polyester polyether copolymer. Commercial        grade soil release polymers (SRPs) from Clariant (TexCare        SRN-240 and TexCare SRN-170) was also used and found to work        well. The basic procedure was as follows:        -   200 mL of surfactant is mixed with 15 L of tap water at            80° C. in a five gallon bucket.        -   The samples to be coated are placed into the diluted            surfactant bucket for five minutes. Each sample is nominally            100 mm wide and 300 mm long. Up to nine samples are placed            in the bucket at one time, with the samples being agitated            for the first ten seconds. The same bucket can be used for            up to 50 samples.        -   Each sample is then removed, held vertically over the bucket            at one corner and residual water drained into the bucket for            five to ten seconds.        -   The samples are rinsed and soaked in a clean bucket of tap            water for at least two minutes. Up to nine samples are            placed in the bucket at one time, with the samples being            agitated for the first ten seconds. The rinse bucket is            changed after one set of nine samples.        -   The sample is dried at 80° C. in a forced air oven until            dry. A typical time is two to three minutes.    -   Holding Capacity: The holding capacity measurement takes the        surfactant coated sample and measures fluid uptake of the        material. The 200 mm×100 mm sample is submerged in tap water at        20° C. for one minute and then removed. The sample is held by        one corner upon removal for 10 seconds and then weighed. The        final weight is divided by the initial weight to calculate the        holding capacity. Holding capacity is measured on as-produced        fabric samples that correspond to conditions measured in the        as-produced fabric thickness test, unless specified otherwise.        These samples are not compression aged before testing. Different        samples sizes can be used in this test. Alternative samples        sizes that can be used are 100 mm×50 mm or 150 mm×75 mm. The        calculation method is the same regardless of the sample size        selected.    -   Wicking Spread Area: The wicking spread is broken down into a MD        and CD spread. A surfactant treated sample is cut that is at        least 30 cm long and 20 cm wide. Non-treated samples do not wick        any fluid. The sample is set on top of a series of petri dishes        (10 cm diameter and 1 cm deep) with one centered in the middle        of the sample and two on either side. 20 mL of distilled water        is then pored onto the sample at a rate of 5 mL per second. The        engraved roll side of the nonwoven is up, facing the fluid        pouring direction. The distance the fluid is wicked is measured        in the MD and CD after one minute. The distilled water can be        colored if needed (Merck Indigocarmin c.i. 73015). The pigment        should not alter the surface tension of the distilled water. At        least three measurements should be made per material. Wicking        spread is measured on as-produced fabric samples that correspond        to conditions measured in the as-produced fabric thickness test,        unless specified otherwise. These samples are not compression        aged before testing. If samples size smaller than 30 cm long and        20 cm wide is used, the sample must first be tested to determine        if the wicking spreads to the edges of the material before one        minute. If the wicking spread in the MD or CD is greater than        the sample width before one minute, the MD horizontal wicking        test height method should be used. The petri dishes are emptied        and cleaned for every measurement.    -   MD Horizontal Transport:

Apparatus

Pipette or Burette: being able to discharge 5.0 ml Tray: size: width: 22cm ± 1 cm, length: 30 cm ± 5 cm, height: 6 cm ± 1 cm Funnel: 250 mlglass funnel attached with valve, orifice diameter: 7 mm Metal clamps:width of clamps: 5 cm Scissors: Suitable for cutting samples for desireddimension Balance: having an accuracy of 0.01 g

Reagent

-   -   Simulated urine: Prepare a 0.9% saline solution (9.0 g/l of        analytical grade sodium chloride in deionized water, with a        surface tension of 70±2 mN/m at 23±2° C. colored with blue        pigment (e.g. Merck Indigocarmin c.i. 73015)

Facilities

-   Conditioned Room . . . Temperature . . . 23° Celsius (±2° C.)    -   Relative Humidity . . . 50% (±2%)

Procedure

-   -   1.) Cut a sample (70±1) mm wide * (300±1) mm long in machine        direction    -   2.) Measure and report the weight (w1) of the sample to the        nearest 0.01 g    -   3.) Clamp the sample with the baby side upwards (textured side        if measuring the structured substrate or engraved roll side if        measuring the base substrate) over the width on the upper edges        of the tray. Material is now hanging freely above the bottom of        the tray.    -   4.) Adjust the outlet of a 250 ml glass funnel attached with a        valve 25.4±3 mm above the sample centered in machine and cross        direction over the sample    -   5.) Prepare the simulated urine    -   6.) Dispense with the pipette or burette 5.0 ml of simulated        urine (4.) into the funnel, while keeping the valve of the        funnel closed    -   7.) Open the valve of the funnel to discharge the 5.0 ml of        simulated urine    -   8.) Wait for a time period of 30 seconds (use stopwatch)    -   9.) Measure the max MD distribution. Report to the nearest        centimeter.    -   Vertical Wicking Height: The vertical wicking test is conducted        by placing a preferred samples size of at least 20 cm long and 5        cm wide sample, held vertically above a large volume of        distilled water. The lower end of the sample is submerged in the        water to at least one cm under the fluid surface. The highest        point the fluid rises to in five minutes is recorded. Vertical        wicking is measured on as-produced fabric samples that        correspond to conditions measured in the as-produced fabric        thickness test, unless specified otherwise. Other sample sizes        can be used, however, the sample width can effect the        measurement when performed on a structured substrate. The        smallest samples width should be 2 cm wide, with a minimum        length of 10 cm.    -   Thermal Stability: Thermal stability of the base substrate or        structured substrate nonwoven is assessed based on how much a 10        cm in MD×at least 2 cm in CD sample shrinks in boiling water        after five minutes. The base substrate should shrink less than        10%, or have a final dimension in the MD of more than 9 cm to be        considered thermally stable. If the sample shrinks more than 10%        it is not thermally stable. The measurement was made by cutting        out the 10 cm by 2 cm sample size, measuring the exact length in        the MD and placing the sample in boiling water for five minutes.        The sample is removed and the sample length measured again        the MD. For all samples tested in the present invention, even        ones with high shrinkage in the comparative examples, the sample        remained flat after the time in the boiling water. Without being        bound by theory, the nonwoven thermal stability depends on the        thermal stability of constituent fibers. If the fibers        comprising the nonwoven shrink, the nonwoven will shrink.        Therefore, the thermal stability measurement here also captures        the thermal stability of the fibers. The thermal stability of        the nonwoven is important for the present invention. For samples        that show significant shrinkage, well beyond the 10% preferred        in the present invention, they can bundle or curl up in boiling        water. For these samples, a 20 gram weight can be attached at        the bottom of the sample and the length measured vertically. The        20 gram weight can be metal binder clips or any other suitable        weight that can attached at the bottom and still enable the        length to be measured.    -   FDT: FDT stands for Fiber Displacement Technology and refers to        mechanical treatment of the base substrate to form a structured        substrate having displaced fibers. If the base substrate is        modified by any type of fiber deformation or relocation, it has        undergone FDT. Simple handling of a nonwoven across flat rollers        or bending is not FDT. FDT implies deliberate movement of fibers        through focused mechanical or hydrodynamic forces for the        intentional movement of fibers in the z-directional plane.    -   Strain Depth: The mechanical straining distance used in the FDT        process.    -   Over Thermal Bond: Designates whether or not the sample has been        overbonded with a second discrete bonding step, using heat        and/or pressure.    -   FS-Tip: Designates whether the tip or top of the displaced        fibers have been bonded.    -   Structured Substrate Density: The structured substrate density        is determined by dividing the actual basis weight by the        structured substrate aged caliper, converting into the same        units and reporting as grams per cubic centimeter.    -   Structured Substrate Specific Volume: The structured substrate        volume is the inverse of structured substrate density in units        of cubic centimeters per gram.    -   Void Volume Creation: Void volume creation refers the void        volume created during the fiber displacement step. Void volume        creation is the difference between the structured substrate        specific volume and the base substrate specific volume.        Aged Strike Through and Rewet Test: For the Strike Through test        Edana method 150.3-96 has been used with the following        modifications:

B. Testing Conditions

-   -   Conditioning of samples and measurement is carried out at 23°        C.±2° C. and 50%±5% humidity

E: Equipment

-   -   As reference absorbing pad 10 layers of Ahlström Grade 989 or        equivalent (av. Strike Through time: 1.7±0.3 s, dimensions:        10×10 cm)

F: Procedure

-   -   2. Reference absorbent pad as described in E    -   3. Test piece is cut into rectangle of 70×125 mm    -   4. Conditioning as described in B    -   5. The test piece is placed on set of 10 plies of filter paper.        For structured substrates the structured side is facing upward.    -   10. The procedure is repeated 60 s after absorption of the        1^(st) gush and the 2^(nd) gush respectively to record the time        of the 2^(nd) and 3^(rd) Strike Through.    -   11. A minimum of 3 tests on test pieces from each specimen is        recommended.        For the measurement of the rewet the Edana method 151.1-96 has        been used with the following modifications:

B. Testing Conditions

-   -   Conditioning of samples and measurement is carried out at 23°        C.±2° C. and 50%±5% humidity

D. Principle

-   -   The set of filter papers with the test piece on top from the        Strike Through measurement is used to measure the rewet.

E. Equipment

-   -   Pick-up paper: Ahlström Grade 632 or equivalent, cut into        dimensions of 62 mm×125 mm, centered on top of the test piece so        that it is not in contact with the reference absorbent pad.    -   Simulated Baby Weight: Total weight 3629 g±20 g

F. Procedure

-   -   12. Start procedure as of step 12 directly after completion of        the 3^(rd) gush of the Strike Through method. The additional        quantity (L) is determined by subtracting the 15 ml of the 3        gushes of the Strike Through test from the total quantity of        liquid (Q) required for the wetback test.    -   21. The wetback value equals the rewet in the present invention.    -   Fiber Properties: Fiber properties in the present invention were        measured using an MTS Synergie 400 series testing system. Single        fibers were mounted on template paper that has been precut to        produce holes that are exactly 25 mm length and 1 cm wide. The        fibers were mounted such that they are length wise straight        across the hole in the paper with no slack. The average fiber        diameter for solid round or equivalent solid round fiber        diameter for non-round is determined by making at least ten        measurements. The average of these ten measurements is used as        the fiber diameter in determining the fiber modulus through the        software input. The fibers were mounted into the MTS system and        the sides of the template paper were cut before testing. The        fiber sample is strained at 50 mm/min speed with the strength        profile initiated with a load force above 0.1 g of force. The        peak fiber load and strain at break are measured with the MTS        software. The fiber modulus is also measured by the MTS at 1%        strain. The fiber modulus as presented in Table 10 was reported        in this manner. The elongation at fiber break and peak fiber        load are also reported in Table 10. The results are an average        of ten measurements. In calculating the modulus of the fibers,        the fiber diameter is used for solid round fibers or the        equivalent solid round fiber diameter is used for non-round or        hollow fibers.    -   Percentage of Broken Filaments: The percentage of broken        filaments at a fiber displacement location can be measured. The        method for determining the number of broken filaments is by        counting. Samples produced having displaced fibers can be with        or without tip bonding. Precision tweezers and scissors are        needed for making actual fiber count measurements. The brand        Tweezerman makes such tools for these measurements, such as        Tweezers with item code 1240T and scissors with item code 3042-R        can be used. Medical Supplier Expert item code MDS0859411 can        also be used for scissors. Other suppliers also make tooling        that can be used.        -   For samples without tip bonding: Generally, one side of the            displaced fiber location will have more broken filaments as            shown in FIG. 16. The structured fibrous web should be cut            on the first surface at the side of the displaced fibers in            the second region with fewer broken filaments. As shown in            FIG. 16, this would be the left side identified as the            1^(st) cut 82. This should be cut along the first surface at            the base of the displaced fibers. The cutting is shown in            FIGS. 17 a and 17 b. The side view shown in FIG. 17 b is            oriented in the MD as shown. Once this cut is made, any            loose fibers should be shaken free or brushed off until no            more fibers fall out. The fibers should be collected and            counted. Then the other side of the second region should be            cut (identified as the 2^(nd) cut 84 in FIG. 16) and the            number of fibers counted. The first cut details the number            of broken fibers. The number of fibers counted in the first            cut and second cut combined equals the total number of            fibers. The number of fibers in the first cut divided by the            total number of fibers times 100 gives the percentage of            broken fibers. In most cases, a visual inspection can show            whether or not the majority of the fibers are broken. When a            quantitative number is needed, the procedure above should be            used. The procedure should be done on at least ten samples            and the total averaged together. If the sample has been            compressed for some time, it may need to be lightly brushed            before cutting to reveal the dislocation area for this test.            If the percentages are close and a statically significant            samples size has not been generated, the number of samples            should be increased by increments of ten to render            sufficient statistical certainty within a 95% confidence            interval.        -   For samples with tip bonding: Generally, one side of the            displaced fiber location will have more broken filaments as            shown in FIG. 18. The side with fewer broken filaments            should be cut first. As shown in FIG. 18, this would be the            left side upper region labeled as the 1^(st) cut, which is            at the top of the where the tip bond is located, but does            not include any of the tip bonded material (i.e., it should            be cut on the side of the tip bond towards the side of the            broken fibers). This cut should be made and loose fibers            shaken free, counted and designated as fiber count 1. The            second cut should be at the base of the displaced fibers,            labeled as the second cut FIG. 18. The fibers should be            shaken loose and counted, with this count designated as            fiber count 2. A third cut is made on the other side of the            tip bonded region, shaken, counted and designated as fiber            count 3. A fourth cut is made at the base of the displaced            fibers, shaken loose and counted and designated as fiber            count 4. The cutting is shown in FIG. 17 a and 17 b. The            number of fibers counted in the fiber count 1 and fiber            count 2 equals the total number of fibers on that side 1-2.            The number of fibers counted in the fiber count 3 and fiber            count 4 equals the total number of fibers on that side 3-4.            The difference between fiber count 1 and fiber count 2 is            determined and then divided by the sum of fiber count 1 and            fiber count 2 then multiplied by 100 and is called broken            filament percentage 1-2. The difference between fiber count            3 and fiber count 4 is determined and then divided by the            sum of fiber count 3 and fiber count 4 then multiplied by            100 and is called broken filament percentage 3-4. For the            present invention broken filament percentage 1-2 or broken            filament percentage 3-4 should be greater than 50%. In most            cases, a visual inspection can show whether or not the            majority of the fibers are broken. When a quantitative            number is needed, the procedure above should be used. The            procedure should be done on at least ten samples and the            total averaged together. If the sample has been compressed            for some time, it may need to be lightly brushed before            cutting to reveal the dislocation area for this test. If the            percentages are close and a statically significant samples            size has not been generated, the number of samples should be            increased by increments of ten to render sufficient            statistical certainty within a 95% confidence interval.    -   In Plane Radial Permeability (IPRP): In plane radial        permeability or IPRP or shortened to permeability in the present        invention is a measure of the permeability of the nonwoven        fabric and relates to the pressure required to transport liquids        through the material. The following test is suitable for        measurement of the In-Plane Radial Permeability (IPRP) of a        porous material. The quantity of a saline solution (0.9% NaCl)        flowing radially through an annular sample of the material under        constant pressure is measured as a function of time.        (Reference: J. D. Lindsay, “The anisotropic Permeability of        Paper” TAPPI Journal, (May 1990, pp 223) Darcy's law and        steady-state flow methods are used for determining in-plane        saline flow conductivity).

The IPRP sample holder 400 is shown in FIG. 20 and comprises acylindrical bottom plate 405, top plate 420, and cylindrical stainlesssteel weight 415 shown in detail in FIG. 21A-C.

Top plate 420 is 10 mm thick with an outer diameter of 70.0 mm andconnected to a tube 425 of 190 mm length fixed at the center thereof.The tube 425 has in outer diameter of 15.8 mm and an inner diameter of12.0 mm. The tube is adhesively fixed into a circular 12 mm hole in thecenter of the top plate 420 such that the lower edge of the tube isflush with the lower surface of the top plate, as depicted in FIG. 21A.The bottom plate 405 and top plate 420 are fabricated from Lexan® orequivalent. The stainless steel weight 415 shown in FIG. 21B has anouter diameter of 70 mm and an inner diameter of 15.9 mm so that theweight is a close sliding fit on tube 425. The thickness of thestainless steel weight 415 is approximately 25 mm and is adjusted sothat the total weight of the top plate 420, the tube 425 and thestainless steel weight 415 is 788 g to provide 2.1 kPa of confiningpressure during the measurement.

As shown in FIG. 21C, bottom plate 405 is approximately 50 mm thick andhas two registration grooves 430 cut into the lower surface of the platesuch that each groove spans the diameter of the bottom plate and thegrooves are perpendicular to each other. Each groove is 1.5 mm wide and2 mm deep. Bottom plate 405 has a horizontal hole 435 which spans thediameter of the plate. The horizontal hole 435 has a diameter of 11 mmand its central axis is 12 mm below the upper surface of bottom plate405. Bottom plate 405 also has a central vertical hole 440 which has adiameter of 10 mm and is 8 mm deep. The central hole 440 connects to thehorizontal hole 435 to form a T-shaped cavity in the bottom plate 405.As shown in FIG. 21B, the outer portions of the horizontal hole 435 arethreaded to accommodate pipe elbows 445 which are attached to the bottomplate 405 in a watertight fashion. One elbow is connected to a verticaltransparent tube 460 with a height of 190 mm and an internal diameter of10 mm. The tube 460 is scribed with a suitable mark 470 at a height of50 mm above the upper surface of the bottom plate 420. This is thereference for the fluid level to be maintained during the measurement.The other elbow 445 is connected to the fluid delivery reservoir 700(described below) via a flexible tube.

A suitable fluid delivery reservoir 700 is shown in FIG. 22. Reservoir700 is situated on a suitable laboratory jack 705 and has an air-tightstoppered opening 710 to facilitate filling of the reservoir with fluid.An open-ended glass tube 715 having an inner diameter of 10 mm extendsthrough a port 720 in the top of the reservoir such that there is anairtight seal between the outside of the tube and the reservoir.Reservoir 700 is provided with an L-shaped delivery tube 725 having aninlet 730 that is below the surface of the fluid in the reservoir, astopcock 735, and an outlet 740. The outlet 740 is connected to elbow445 via flexible plastic tubing 450 (e.g. Tygon®). The internal diameterof the delivery tube 725, stopcock 735, and flexible plastic tubing 450enable fluid delivery to the IPRP sample holder 400 at a high enoughflow rate to maintain the level of fluid in tube 460 at the scribed mark470 at all times during the measurement. The reservoir 700 has acapacity of approximately 6 liters, although larger reservoirs may berequired depending on the sample thickness and permeability. Other fluiddelivery systems may be employed provided that they are able to deliverthe fluid to the sample holder 400 and maintain the level of fluid intube 460 at the scribed mark 470 for the duration of the measurement.

The IPRP catchment funnel 500 is shown in FIG. 20 and comprises an outerhousing 505 with an internal diameter at the upper edge of the funnel ofapproximately 125 mm. Funnel 500 is constructed such that liquid fallinginto the funnel drains rapidly and freely from spout 515. A horizontalflange 520 around the funnel 500 facilitates mounting the funnel in ahorizontal position. Two integral vertical internal ribs 510 span theinternal diameter of the funnel and are perpendicular to each other.Each rib 510 s 1.5 mm wide and the top surfaces of the ribs lie in ahorizontal plane. The funnel housing 500 and ribs 510 are fabricatedfrom a suitably rigid material such as Lexan® or equivalent in order tosupport sample holder 400. To facilitate loading of the sample it isadvantageous for the height of the ribs to be sufficient to allow theupper surface of the bottom plate 405 to lie above the funnel flange 520when the bottom plate 405 is located on ribs 510. A bridge 530 isattached to flange 520 in order to mount a dial gauge 535 to measure therelative height of the stainless steel weight 415. The dial gauge 535has a resolution of ±0.01 mm over a range of 25 mm. A suitable digitaldial gauge is a Mitutoyo model 575-123 (available from McMaster CarrCo., catalog no. 19975-A73), or equivalent. Bridge 530 has two circularholes 17 mm in diameter to accommodate tubes 425 and 460 without thetubes touching the bridge.

Funnel 500 is mounted over an electronic balance 600, as shown in FIG.20. The balance has a resolution of ±0.01 g and a capacity of at least2000 g. The balance 600 is also interfaced with a computer to allow thebalance reading to be recorded periodically and stored electronically onthe computer. A suitable balance is Mettler-Toledo model PG5002-S orequivalent. A collection container 610 is situated on the balance pan sothat liquid draining from the funnel spout 515 falls directly into thecontainer 610.

The funnel 500 is mounted so that the upper surfaces of ribs 510 lie ina horizontal plane. Balance 600 and container 610 are positioned underthe funnel 500 so that liquid draining from the funnel spout 515 fallsdirectly into the container 610. The IPRP sample holder 400 is situatedcentrally in the funnel 700 with the ribs 510 located in grooves 430.The upper surface of the bottom plate 405 must be perfectly flat andlevel. The top plate 420 is aligned with and rests on the bottom plate405. The stainless steel weight 415 surrounds the tube 425 and rests onthe top plate 420. Tube 425 extends vertically through the central holein the bridge 530. The dial gauge 535 is mounted firmly to the bridge530 with the probe resting on a point on the upper surface of thestainless steel weight 415. The dial gauge is set to zero in this state.The reservoir 700 is filled with 0.9% saline solution and re-sealed. Theoutlet 740 is connected to elbow 445 via flexible plastic tubing 450.

A an annular sample 475 of the material to be tested is cut by suitablemeans. The sample has an outer diameter of 70 mm and an inner holediameter of 12 mm. One suitable means of cutting the sample is to use adie cutter with sharp concentric blades.

The top plate 420 is lifted enough to insert the sample 475 between thetop plate and the bottom plate 405 with the sample centered on thebottom plate and the plates aligned. The stopcock 735 is opened and thelevel of fluid in tube 460 is set to the scribed mark 470 by adjustingthe height of the reservoir 700 using the jack 705 and by adjusting theposition of the tube 715 in the reservoir. When the fluid level in thetube 460 is stable at the scribed mark 470 and the reading on the dialgauge 535 is constant, the reading on the dial gauge is noted (initialsample thickness) and the recording of data from the balance by thecomputer is initiated. Balance readings and time elapsed are recordedevery 10 seconds for five minutes. After three minutes the reading onthe dial gauge is noted (final sample thickness) and the stopcock isclosed. The average sample thickness L_(p) is the average of the initialsample thickness and the final sample thickness expressed in cm.

The flow rate in grams per second is calculated by a linear leastsquares regression fit to the data between 30 seconds and 300 seconds.The permeability of the material is calculated using the followingequation:

$k = \frac{\left( {Q/\rho} \right)\mu \; {\ln \left( {R_{o}/R_{i}} \right)}}{2\; \pi \; L_{p}\Delta \; P}$

where:

k is the permeability of the material (cm²)

Q is the flow rate (g/s)

ρ is the density of the liquid at 22° C. (g/cm³)

μ is the viscosity of the liquid at 22° C. (Pa·s)

R_(o) is the sample outer radius (mm)

R_(i) is the sample inner radius (mm)

L_(p) is average sample thickness (cm)

ΔP is the hydrostatic pressure (Pa)

$\Delta \; {P\left( {{\Delta \; h} - \frac{L_{p}}{2}} \right)}G\; \rho \; 10$

where:

Δh is the height of the liquid in tube 460 above the upper surface ofthe bottom plate (cm), and

G is the gravitational acceleration constant (m/s²)

$K_{r} = \frac{k}{\mu}$

where:

K_(r) is the IPRP value expressed in units of cm²/(Pa·s)

Discussion of Data in Tables: The information below will provide a basisfor including the information found in the tables in the invention.

-   -   Table 1 and Table 2: Base substrate material properties for        pronounced trilobal shaped fibers, solid round and standard        trilobal base substrate as-produced properties. Table 1        describes the base substrate as-produced properties. The table        lists the specifics for each example. The important properties        to point out in Table 1 are the modification ratio for the        pronounced trilobal filaments and the relatively low MD        elongation for these point bonded PET substrates.    -   Table 3: The fluid handling properties of the base substrate are        shown. The Holding Capacity of these base substrates indicated        that they are not absorbent materials, with gram per gram        holding capacities below 10.    -   Table 4: Lists the process settings and property changes of        structured substrates versus the base substrate properties. The        examples for the 1D collection of samples highlight a primary        purpose in the present invention. 1D is the base substrate (60        g/m² 6.9 dpf PET) while 1D1 through 1D6 show the changes in        caliper with increasing fiber displacement, as indicated by the        strain depth. Increasing strain increases caliper. The over        bonding is indicated by the over thermal bonding. Tip bonding is        indicated by FS-Tip and as shown, can also affect the aged        caliper and the amount of void volume created. The purpose of        the present invention is to create void volume for liquid        acquisition. The over thermal bonding also can be used to        increase mechanical properties, as illustrated in the MD tensile        strength increase vs. the base substrate. The Example 1N data        set compare the base substrate with 1N1 through 1N9, which have        undergone different strain depth processes. This data set shows        that there is an optimization in caliper generation that is        determined by any over thermal bonding, FS-tip and overall        strain. The data shows that too much strain can produce samples        with worse aged caliper. In one execution of the present        invention, this would correspond to completely broken filament        in the activated region, while the region with the highest void        volume creation has the preferred broken filament range. The        results also show that similar structured substrate volumes can        be created for the present invention as typical resin bonded        structures, while also having fluid transport properties.    -   Table 5: The data and example show that the caliper increase and        void volume creation in the present invention can be used for        fiber shapes standard trilobal and solid round. The benefit of        the present invention is not restricted to pronounced trilobal        fibers.    -   Table 6 lists fluid handling properties of structured substrates        vs. base substrate properties. The examples in Table 6 are the        same as Table 4. The data in Table 6 show that the use of FDT        does increase the MD Horizontal Transport properties of the        structured substrate vs. the base substrate. The over bonding        has been found to increase fluid transport in the MD. The        Vertical wicking height component shows similar properties of        the structured substrate vs. the base substrate at moderate FDT        strains, but at higher strains the Vertical wicking height        component does decrease slightly. Relative to the carded resin        bonded nonwovens; the vertical transport component is still very        good. The aged strike through data shows a dramatic improvement        of fluid acquisition rates of the structured substrate vs. the        base substrate. The strike through times decreases dramatically        with FDT vs. the base substrate. The rewet properties generally        decrease with FDT vs. the base substrate. The data in this Table        6 demonstrates the structured substrate's ability to provide        fluid transport along with the ability to control the fluid        acquisition rates. The table also includes the fluid        permeability of a material via IPRP on the samples, which shows        the dramatic improvement after FDT, and also how the structured        substrates have higher permeability at calipers similar to the        carded resin bonded structures.    -   Table 7 lists some additional fluid handling properties of some        pronounced fiber shaped structured substrates vs. base        substrates. The activation conditions used in the sample        description are listed in Table 5. Table 5 shows that changes in        FDT can improve fluid acquisition rates.    -   Table 8 shows additional structured substrate vs. base substrate        samples with improved fluid acquisition rates for solid round        (SR) and standard trilobal fibers (TRI). The activation        conditions used for the structured substrate samples are        provided in Table 9.    -   Table 9 lists the process conditions for the samples made in        Table 8.    -   Table 10 lists the single fiber property values for substrates        used in the present invention. Because the present invention        uses high speed fiber spinning to produce thermal stable PET,        the modulus values are very high for fibers having strength >10        g per filament.

TABLE 1 Base Substrate example material properties. Acutal MD MD CD CDBasis Aged Actual Tensile Elongation Tensile Elongation at Example MassWeight Caliper Mod Denier Strength at Peak Strength Peak MD/CDDesignation Resin Type Throughput Shape (g/m²) (mm) Ratio (dpf) (N/5 cm)(%) (N/5 cm) (%) Ratio 1D F61HC/9921 3GHM p-TRI 60.6 0.36 1.72 6.9 96.94 60.3 33 1.61 1F F61HC/9921 4GHM p-TRI 41.1 0.35 2.09 8.6 80.6 26 39.535 2.04 1N F61HC/9921 4GHM p-TRI 44.1 0.39 1.72 6.9 61.7 5 36.2 36 1.71O F61HC/9921 4GHM p-TRI 67.0 0.43 1.72 6.9 120.0 6 67.2 33 1.8 2K F61HC4GHM p-TRI 40.6 0.32 1.98 9.2 82.5 28 38.2 32 2.16 3E F61HC/9921 4.0std- 41.7 0.29 1.18 10.5 74.3 29 42.5 41 1.75 TRI 4B F61HC/9921 3GHM SR42.7 0.36 N/A 4.9 58.0 24.0 50.2 39.0 1.2

TABLE 2 Base Substrate material properties. Actual Base Base EquivalentBasis Substrate Substrate Fiber SR Fiber Weight Aged Specific SpecificExample Perimeter Diameter (g/m²) Caplier Opacity Density VolumeDesignation (μm) (μm) (g/m²) (mm) (%) (g/m3) (cm3/g) 1D 99.7 26.8 60.60.36 40 168333 5.94 1F 135.5 30.0 41.1 0.35 25 117429 8.52 1N 135.5 30.044.1 0.39 113077 8.84 1O 135.5 30.0 67.0 0.43 155814 6.42 2K 138.0 31.040.6 0.32 126875 7.88 3E 33.2 118 41.7 0.29 26 143793 6.95 4B 71.0 22.642.7 0.36 16 118611 8.43

TABLE 3 Base Substrate fluid handling properties. Bonding HoldingVertical Line Temperature, Capacity Wicking Wicking Example SpeedEngraved/Smooth w/SRP Spread Height Thermally % Designation (m/min) (°C.) Surfactant (g/g) MD (cm) CD (cm) (mm) FDT Stable? Shrinkage 1D 23200/190 DP988A 4.33 26.0 16.0 108 NO YES 2 1F 43 200/190 DP988A 5.2018.0 16.0 27 NO YES 5 1N 44 210/200 DP988A 19 17 51 NO YES 2 1O 30210/200 DP988A 30 21 80 NO YES 0 2K 43 200/190 DP988A 5.30 13.0 11.0 NOYES 3 3E 43 200/190 DP988A 4.8 2.5 2.5 22 NO YES 2 4B 31 200/190 DP988A4.00 11.9 9.0 29 NO YES 4

TABLE 4 Mechanical Property changes of Base Substrate vs. Structuredsubstrate. Base Structured Substrate Substrate Void MD MD Strain LineOver Fresh Aged Specific Specific Volume Tensile Elongation ExampleBasis Weight Depth Speed Thermal Caliper Caliper Volume Volume CreationStrength at Peak Designation (g/m²) FDT (inches) (MPM) Bond FS-Tip (mm)(mm) (cm3/g) (cm3/g) (cm3/g) N/5 cm) (%) 1D 60.1 NO NO NO NO NO 0.360.35 5.82 96.3 4 1D1 60.1 YES 0.01 17 YES NO No Data No Data 90.5 5 1D260.1 YES 0.01 17 YES NO 0.42 0.38 6.32 0.50 154.1 26 1D3 60.1 YES 0.0717 YES NO 0.53 0.48 7.99 2.16 147.7 23 1D4 60.1 YES 0.07 17 YES YES NoData No Data 152.1 26 1D5 60.1 YES 0.13 17 YES YES 0.90 0.74 12.31 6.49127.6 37 1D6 60.1 YES 0.13 17 YES NO 0.84 0.58 9.65 3.83 109.8 41 ResinBond 43 NO NO NO NO NO 0.80 0.63 14.65 43 g/m² Resin Bond 60 NO NO NO NONO 1.14 0.91 15.17 60 g/m² 1N 44.1 NO NO NO NO NO 0.4  0.4  9.07 0.001N1 44.1 YES 0.1  17 YES NO 0.84 0.72 16.33 7.26 1N2 44.1 YES 0.1  17YES YES 0.76 0.7  15.87 6.80 1N3 44.1 YES 0.1  17 NO NO 0.91 0.79 17.918.84 1N4 44.1 YES 0.1  17 NO YES 0.75 0.65 14.74 5.67 1N5 44.1 YES 0.1317 YES YES 1.2  0.83 18.82 9.75 1N6 44.1 YES 0.13 17 YES NO 1.31 0.6915.65 6.58 1N9 44.1 YES 0.16 17 YES YES 1.17 0.65 14.74 5.67

TABLE 5 Mechanical Property changes of Base Substrate vs. StructuredSubstrate. Base Structured Substrate Substrate Void Strain Line OverFresh Aged Specific Specific Volume Example Basis Weight Depth SpeedThermal Caliper Caliper Volume Volume Creation Designation (g/m²) FDT(inches) (MPM) Bond FS-Tip (mm) (mm) (cm3/g) (cm3/g) (cm3/g) 1O 67.0 NONO NO NO NO 0.43 0.43 6.42 0.00 1O1 67.0 YES 0.1  17 YES NO 0.89 0.8011.94 5.52 1O2 67.0 YES 0.1  17 YES YES 0.81 0.75 11.19 4.78 1O3 67.0YES 0.1  17 NO NO 0.99 0.86 12.84 6.42 1O4 67.0 YES 0.13 17 YES NO 1.451.00 14.93 8.51 1O5 67.0 YES 0.13 17 YES YES 1.31 1.11 16.57 10.15 1O667.0 YES 0.13 17 NO NO 1.34 0.90 13.43 7.01 1K 40.6 NO NO NO NO NO 0.320.32 7.88 0.00 1K1 40.6 YES 0.13 17 YES YES 0.94 0.48 11.82 3.94 1F 41.1NO NO NO NO NO 0.35 0.35 8.52 0.00 1F1 41.1 YES 0.13 17 YES YES 0.920.52 12.65 4.14 4B 42.7 NO NO NO NO NO 0.36 0.36 8.43 0.00 4B1 42.7 YES0.07 17 YES YES 0.56 0.49 11.48 3.04 4B2 42.7 YES 0.13 17 YES YES 1.070.50 11.71 3.28 3E 41.7 NO NO NO NO NO 0.31 0.31 7.43 0.00 3E1 41.7 YES0.07 17 YES YES 0.42 0.33 7.91 0.48 3E2 41.7 YES 0.13 17 YES YES 0.620.38 9.11 1.68

TABLE 6 Fluid Management Properties of Base Substrate and StructuredSubstrates. MD Vertical Aged Aged Aged Fresh Aged Horizontal WickingStrike Strike Strike Example Caliper Caliper IPRP Transport HeightThrough 1 Through 2 Through 3 Rewet Designation (mm) (mm) FDT cm²/(Pa s)(cm) (cm) (s) (s) (s) (g) 1D 0.36 0.35 NO 5,060 19.5 10.8 1.2 1.8 1.71.5 1D1 No Data No Data YES 20.0 10.7 1D2 0.42 0.38 YES 11,200 23.0 10.80.5 1.2 1.4 0.8 1D3 0.53 0.48 YES 13,400 25.0 11.0 0.6 1.3 1.3 2.0 1D4No Data No Data YES 25.0 9.0 1D5 0.90 0.74 YES 24,500 27.0 8.0 0.4 0.70.7 0.2 1D6 0.84 0.58 YES 17,300 23.0 8.0 0.6 0.7 0.5 0.1 Resin Bond0.80 0.63 NO 11,900 2 0 0.7 1.2 1.1 0.0 43 g/m² Resin Bond 1.14 0.91 NO13,200 2 0 0.5 1.0 0.9 0.1 60 g/m² 1N 0.4  0.4  NO 7,900 19.0 8.1 1.21.4 1.6 1.3 1N1 0.84 0.72 YES 29,439 20.0 8.2 0.3 0.7 0.6 0.9 1N2 0.760.7  YES 30,320 21.0 8.4 0.4 0.9 0.9 1.2 1N3 0.91 0.79 YES 22,934 21.08.3 0.2 0.8 0.8 0.9 1N4 0.75 0.65 YES 19,132 22.0 7.8 0.4 1.0 0.6 1.51N5 1.2  0.83 YES 24,634 22.0 7.7 0.0 0.7 0.6 0.2 1N6 1.31 0.69 YES17,455 21.0 7.7 0.4 0.7 0.4 0.5 1N9 1.17 0.65 YES 10,795 22.5 6.8 0.00.6 0.6 0.2

TABLE 7 Fluid Management Properties of Base Substrate and Structuredsubstrates. MD Vertical Aged Aged Aged Fresh Aged Horizontal WickingStrike Strike Strike Example Caliper Caliper IPRP Transport HeightThrough 1 Through 2 Through 3 Rewet Designation (mm) (mm) FDT cm²/(Pa s)(cm) (cm) (s) (s) (s) (g) 1O 0.43 0.43 NO 5,060 30.0 13.5 1.2 1.8 1.71.5 1O1 0.89 0.80 YES 31,192 32.0 13.7 0.0 0.1 0.5 1.8 1O2 0.81 0.75 YES32,134 33.0 14.1 0.6 0.5 0.8 1.9 1O3 0.99 0.86 YES 29,158 33.0 12.6 0.10.5 0.2 1.8 1O4 1.45 1.00 YES 32,288 32.5 12.3 0.2 0.3 0.4 0.5 1O5 1.311.11 YES 39,360 33.0 12.4 0.4 0.1 0.3 0.5 1O6 1.34 0.90 YES 26,298 32.012.5 0.0 0.1 0.5 0.7

TABLE 8 Fluid Management Properties of Different Shaped Fibers. MDVertical Aged Aged Aged Fresh Aged Horizontal Wicking Strike StrikeStrike Example Fiber Caliper Caplier Transport Height Through 1 Through2 Through 3 Rewet Designation Shape (mm) (mm) FDT (cm) (cm) (s) (s) (s)(g) 3E TRI 0.29 0.29 NO 2.5 2.2 1.1 1.3 1.6 1.2 3E1 TRI 0.48 0.42 YES4.0 2.9 0.49 1.01 1.03 0.29 3E2 TRI 0.66 0.48 YES 3.0 2.7 0.53 0.73 0.700.33 4B SR 0.36 0.36 NO 11.9 2.9 1.3 1.5 1.7 1.3 4B1 SR 0.43 0.41 YES14.1 4.8 0.79 1.10 1.13 0.71 4B2 SR 0.56 0.52 YES 13.2 4.6 0.60 0.940.93 0.07 Resin Bond 0.80 0.63 2 0 0.68 1.19 1.10 0.04 43 g/m² ResinBond 1.14 0.91 2 0 0.49 1.04 0.85 0.06 60 g/m²

TABLE 9 Process settings for samples in Table 8. Over Example StrainLine Thermal Fresh Aged Desig- Depth Speed Bond FS- Caliper Calipernation FDT (inches) (MPM) (inches) Tip (mm) (mm) 4B1 YES 0.07 17 YES YES0.48 0.42 4B2 YES 0.13 17 YES YES 0.66 0.48 3E1 YES 0.07 17 YES YES 0.430.41 3E2 YES 0.13 17 YES YES 0.56 0.52

TABLE 10 Single fiber property data for sample used in presentinvention. Fiber Peak Fiber Strain at Polymer Denier Load Break ModulusFiber Shape Type (dpf) (g) (%) (GPa) Pronounced Trilobal PET 6.9 15.1 944.3 Pronounced Trilobal PET 8.6 15.6 126 3.5 Pronounced Trilobal PET10.7 15.3 170 3.2 Pronounced Trilobal PET 13.0 15.5 186 3.4 StandardTrilobal PET 6.5 15.3 165 3.8 Standard Trilobal PET 9.6 15.9 194 2.7Standard Trilobal PET 10.5 16.0 247 2.4 Standard Trilobal PET 14.5 17.5296 2.6 Solid Round PET 2.9 10.0 167 3.0 Solid Round PET 4.9 15.6 2682.8 Solid Round PET 8.9 15.9 246 3.3

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A disposable absorbent article comprising: a chassis including atopsheet and a backsheet; an absorbent core located between the topsheetand the backsheet; and an acquisition system located between thetopsheet and the absorbent core, wherein the acquisition system includesa structured fibrous web comprising thermoplastic fibers having amodulus of at least about 0.5 GPa forming a fibrous web that isthermally stable; the structured fibrous web comprising a first surfaceand a second surface, a first region and a plurality of discrete secondregions disposed throughout the first region, the second regions formdiscontinuities on the second surface and displaced fibers on the firstsurface wherein at least about 50% and less than about 100% of thedisplaced fibers in each second region are fixed along a first side ofthe second region and separated proximate to the first surface along asecond side of the second region opposite the first side forming looseends extending away from the first surface, wherein the displaced fibersforming loose ends create void volume for collecting fluid.
 2. Thedisposable absorbent article of claim 1, wherein the structured fibrousweb further comprises a plurality of overbonded regions disposedthroughout the first region.
 3. The disposable absorbent article ofclaim 1, wherein in each of the overbonded regions of the structuredfibrous web, the first region and the second regions have an agedcaliper wherein the aged caliper of the second regions formed by theloose ends of the displaced fibers is less than about 1.5 mm which isgreater than the aged caliper of the first region and the aged caliperof the first region is greater than the aged caliper of the overbondedregions.
 4. The disposable absorbent article of claim 1, wherein thethermally stable fibrous web allow shrinkage of less than about 30%. 5.The disposable absorbent article of claim 1, wherein the fibers of thestructured fibrous web are continuous spunbond fibers.
 6. The disposableabsorbent article of claim 5, wherein the spunbond fibers of thestructured fibrous web are uncrimped.
 7. The disposable absorbentarticle of claim 2 wherein the overbonded regions of the structuredfibrous web are continuous.
 8. The disposable absorbent article of claim2 wherein the overbonded regions of the structured fibrous web form acontinuous network.
 9. The disposable absorbent article of claim 2wherein the overbonded regions of the structured fibrous web cover lessthan about 75% of the total surface area of the first surface or thesecond surface of the fibrous web.
 10. The disposable absorbent articleof claim 1, wherein in the structured fibrous web the loose ends of thedisplaced fibers are thermally bonded together.
 11. The disposableabsorbent article of claim 1, wherein in the structured fibrous web thesecond regions form less than about 75% of the total surface area of thefirst surface or the second surface of the fibrous web.
 12. Thedisposable absorbent article of claim 1, wherein the structured fibrousweb is non-extensible.
 13. The disposable absorbent article of claim 1,wherein the fibers of the structured fibrous web are non-extensible. 14.The disposable absorbent article of claim 1, wherein the fibers of thestructured fibrous web are formed from a thermoplastic polymercomprising polyester.
 15. The disposable absorbent article of claim 1,wherein the fibers of the structured fibrous web comprise PET.
 16. Thedisposable absorbent article of claim 1, the fibers of the structuredfibrous web comprise PET and coPET.
 17. The disposable absorbent articleof claim 1, wherein the fibers of the structured fibrous web comprisemulti-lobal shaped fibers.
 18. The disposable absorbent article of claim17, wherein the multi-lobal shaped fibers comprise fibers selected fromthe group consisting of trilobal shape, delta shape, star shape,triangular shape and combinations thereof.
 19. The disposable absorbentarticle of claim 1, wherein the fibers of the structured fibrous webhave a modulus of at least about 2.0 GPa.
 20. The disposable absorbentarticle of claim 1, wherein the fibers of the structured fibrous webhave a modulus of at least about 3.0 GPa.
 21. The disposable absorbentarticle of claim 1, wherein the fibers of the structured fibrous webhave a denier of at least about 3 dpf.
 22. The disposable absorbentarticle of claim 1, wherein the structured fibrous web has a structuredsubstrate specific volume of at least about 5 cm3/g.
 23. The disposableabsorbent article of claim 1, wherein the structured fibrous web ishydrophilic.
 24. A disposable absorbent article comprising: a chassisincluding a topsheet and a backsheet; an absorbent core located betweenthe topsheet and the backsheet; and an acquisition system locatedbetween the topsheet and the absorbent core, wherein the acquisitionsystem includes a structured fibrous web comprising non extendablethermoplastic fibers having a modulus of at least about 0.5 GPa, thestructured fibrous web being formed from a base substrate, the basesubstrate being a fully bonded, non extensible fibrous base web that isthermally stable; the structured fibrous web comprising a first surfaceand a second surface, a first region and a plurality of discrete secondregions disposed throughout the first region, the second regions formdiscontinuities on the second surface and displaced fibers on the firstsurface, wherein the displaced fibers forming loose ends create voidvolume for collecting fluid.
 25. The disposable absorbent article ofclaim 24, wherein the absorbent core comprises absorbent materialcomprising absorbent particulate polymer material, the absorbentparticulate polymer material being present in an amount greater thanabout 80% by weight of the absorbent material of the absorbent core.